description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
|---|---|---|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is related to, claims the earliest available effective filing date(s) from (e.g., claims earliest available priority dates for other than provisional patent applications; claims benefits under 35 USC §119(e) for provisional patent applications), and incorporates by reference in its entirety all subject matter of the following listed application(s) (the “Related Applications”) to the extent such subject matter is not inconsistent herewith; the present application also claims the earliest available effective filing date(s) from, and also incorporates by reference in its entirety all subject matter of any and all parent, grandparent, great-grandparent, etc. applications of the Related Application(s) to the extent such subject matter is not inconsistent herewith:
[0002] U.S. provisional patent application 62/043746 entitled “Electronic Psychrometer and/or Humidistat with Low Temperature and High Humidity Capability”, naming Christopher W. Callahan as inventor, filed 29 Aug. 2014.
BACKGROUND
[0003] 1. Field of Use
[0004] This invention relates to an improved apparatus fir measuring relative humidity. More specifically, the invention relates to a high precision electronic. Psychrometer operable at low temperatures and high humidity environments.
[0005] 2. Description of Prior Art (Background)
[0006] In general a psychrometer is an instrument consisting of two thermometers which are used in the measurement of the moisture content, or relative humidity (RH) of air or other gases. The bulb or sensing area of one of the thermometers either is covered by a thin piece of clean muslin cloth, or other wick material, wetted uniformly with distilled water or is otherwise coated with a film of distilled water. The temperatures of both the bulb and the air contacting the bulb are lowered by the evaporation which takes place when unsaturated air moves past the wetted bulb. An equilibrium temperature, termed the wet-bulb temperature will be reached; the equilibrium temperature closely approaches the lowest temperature to which air can be cooled by the evaporation of water into the unsaturated air. Moisture parameters, such as relative humidity and dew-point temperature, can be evaluated from the wet- and dry-bulb measurements by means of psychrometric tables and generally accepted closed form formulae for calculating water/air mixtures.
[0007] Relative Humidity (RH) is a measure of the degree to which air is saturated with water compared to the highest level of saturation at a given temperature. This is a ratio of the partial pressure (proportional content) of water in air at the actual conditions to the partial pressure of water in air at saturation (100% RH). Partial pressures of water in air are related to temperature.
[0008] The traditional method for determining RH is to use a manual sling Psychrometer which has two thermometers, one with a dry bulb and one with a wet bulb. The dry bulb thermometer is typical of thermometers in use in other applications and simply measures the air temperature. The wet bulb thermometer has a water saturated wick around it. When the thermometer is swung in the air to move air over the wet bulb, evaporation of water from this wick depresses the temperature of the bulb to a degree that corresponds to the saturation partial pressure of water in the air at the dry bulb temperature. Comparison of these two temperatures can provide an indirect measure of RH.
[0009] However, the long-term (6-12 month) storage of crops requires control of both storage temperature and humidity. Storage temperature is depressed to 32-40 degrees F. (crop dependent) in order to minimize the rate of respiration in the crops. Humidity is generally raised to 80-98% RH to reduce desiccation yet still avoid liquid water condensation on the crops. In recent field research pertaining to improved crop storage methods, it has been determined that there is a lack of suitable equipment for humidity measurement and control at low storage temperatures and high humidity.
[0010] The vast majority of humidity sensing equipment available is based on moisture absorbing, materials whose capacitance changes depending on the material moisture content. These sensors tend to have a precision of +/−2% RH from 20-80% RH at 70 degrees F., but then lose precision in the higher RH range and lower temperature range, straying, to +/−5% RH. It is this range that is most needed by those storing winter crops. Some sensors exist which demonstrate +/−2% RH precision up to 98% RH. But in all of these sensor types, excursions to 100% RH results in reduced precision and accuracy and can cause a mechanical failure or a need for recovery (heat and dry) in order to reuse the sensor. Additionally, these sensors may also suffer an unrecoverable electronic failure.
[0011] Thus, there is a technical challenge which exists in the measurement of high humidity in low temperature conditions; and, therefore control of equipment (e.g., humidifiers, dehumidifiers) based on these measurements.
BRIEF SUMMARY
[0012] The foregoing and other problems are overcome, and other advantages are realized, in accordance with the presently preferred embodiments of these teachings.
[0013] An electronic device for measurement of dry bulb and wet bulb space temperatures is disclosed. A microprocessor contains necessary software to calculate relative humidity from the dry and wet bulb space temperatures and to adjust an output as necessary to control humidity and/or temperature of the space.
[0014] The invention is also directed towards an electronic psychrometer having wet and dry temperature sensors, wherein the temperature sensors are substantially 10 k Ohm +/−0.05 deg. C. thermistors. The invention also includes a fan-less evaporator cage surrounding the thermistors, wherein the evaporator cage, or wick, comprises pick dimension P, wherein pick dimension P is the number of carrier crossings per longitudinal inch of the evaporator cage. Also included is a programmable controller and a computer readable medium, operatively coupled to the programmable controller. The computer readable medium contains a set of programmable controller instructions that, if executed by the programmable controller, are operable to: calibrate the wet and dry temperature sensors; and determine relative humidity with an accuracy of substantially +/−1% RH at 32 degrees F.
[0015] In accordance with one embodiment of the present invention an electronic psychrometer is provided. The electronic psychrometer includes a dry temperature sensor and a wet temperature sensor. An evaporator cage surrounds the at least one wet temperature sensor, wherein the evaporator cage comprises pick dimension P, wherein pick dimension P is the number of carrier crossings per longitudinal inch of the evaporator cage. Also include is a programmable controller and a computer readable medium, operatively coupled to the programmable controller. The computer readable medium contains a set of programmable controller instructions that, if executed by the programmable controller, are operable to determine relative humidity with an accuracy of substantially +/−1% RH at 32 degrees F.
[0016] The invention is also directed towards a method for calibrating an electronic psychrometer. The method includes providing a reference fluid having a known temperature. The method also includes providing wet and dry temperature sensors. The wet and dry temperature sensors are immersed or enveloped within the reference fluid and the temperatures reported by the sensors is compared to the known temperature of the reference fluid. A calibration temperature offset is determined from the difference between the reported temperatures and the known temperature.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the chums at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0018] FIG. 1 is a pictorial illustration of an electronic psychrometer system in which the invention is implemented;
[0019] FIG. 2 is a pictorial illustration of a self-ventilating and adjustable ventilation cover plate in accordance with the invention shown in FIG. 1 ;
[0020] FIG. 3 is a pictorial illustration of a system of psychrometer systems in accordance with the invention shown in FIG. 1 ; and
[0021] FIG. 4 is an illustration of one method for calibrating the wet/dry thermistors in accordance with the invention shown in FIG. 1 .
DETAILED DESCRIPTION
[0022] The following brief definition of terms shall apply throughout the application:
[0023] The term “comprising” means including but not limited to, and should be interpreted in the manner it is typically used in the patent context;
[0024] The phrases “in one embodiment,” “according to one embodiment,” and the like generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present invention, and may be included in more than one embodiment of the present invention (importantly, such phrases do not necessarily refer to the same embodiment);
[0025] If the specification describes something as “exemplary” or an “example,” it should be understood that refers to a non-exclusive example; and
[0026] If the specification states a component or feature “may,” “can,” “could,” “should,” “preferably,” “possibly,” “typically,” “ooptionally,” “for example,” or “might” (or other such language) be included or have a characteristic, that particular component or feature is not required to be included or to have the characteristic.
[0027] As noted earlier psychrometry is the principle whereby the measurement of a gas (often air) humidity is determined from simultaneous dry bulb thermometer and wet bulb thermometer measurements. The dry bulb thermometer measures the temperature of the gas. The temperature of the wet bulb thermometer depends on both the dry bulb temperature (e.g., ambient temperature) and humidity of the gas. The rate of evaporation of water from the wet bulb thermometer depends on the amount of water vapor present in the surrounding gas. The temperature of the wet bulb thermometer results from a balance between the evaporative cooling and convective heating by the ambient gas flows.
[0028] Wet-bulb and dry-bulb temperatures are digitally measured and relative humidity measurement proceeds by standard psychrometric equations. Water vapor pressure is estimated from the wet bulb and dry thermometer temperatures using the psychrometric equation,
[0000] e=e s ( t w )−λ( t d −t w ) eq. 1
[0000] where e is the vapor pressure, e s (t w ) is the saturated vapor pressure at the wet bulb temperature (t w ), t d is dry bulb temperature, and λ=0.660 (mb/° C.) when barometric pressure is 1000 mb.
[0029] Relative humidity is the ratio of actual water vapor present in gas to the maximum quantity which could saturate at the gas temperature. Thus, relative humidity (RH) is given by:
[0000] RH= 100 e/e s ( t d ) eq. 2
[0030] Referring now to FIG. 1 , there is shown a diagram layout of an electronic psychrometer system 100 in which the invention is implemented. Included within the system 100 is remote temperature differentiator housing 11 . Differentiator housing 11 includes wet bulb temperature sensor 13 , dry bulb temperature sensor 12 , wick 17 , and evaporation controller 14 . Also, shown in FIG. 1 is optional fan 500 .
[0031] Still referring to FIG. 1 , wet bulb temperature sensor 13 is a high accuracy negative temperature coefficient (NTC) thermistor (e.g., 10 kOhm +/−0.05 deg C.: US Sensor # PR103J2). It will be understood that temperature sensor 13 is referred to as a wet “bulb” temperature sensor and that the term bulb is common language stemming from sensors using liquid thermometers. Similar to web bulb temperature sensor 13 , dry bulb temperature sensor 12 is also a high accuracy NTC thermistor. It will be appreciated that wet and dry bulb sensors 12 , 13 may be substantially matched (electrical characteristics) NTC thermistors or offset (electrical characteristics) by a predetermined amount. In alternate embodiments the thermistors may be high accuracy positive temperature coefficient (PTC) thermistors, thermocouples (TC), or resistive thermal devices (RTD).
[0032] Still referring to FIG. 1 , housing 11 may be any suitable shape or size to facilitate the balance between the evaporative cooling and convective heating by the ambient gas flows discussed earlier. It will be appreciated that in alternate embodiments the color of the housing 11 may be chosen to exploit air mixing by thermal or solar radiation. For example, the housing 11 may be colorized black to increase the internal ambient temperature and further facilitate the balanced discussed herein. Housing 11 may also be variably colorized to promote heating effects within one section of housing 11 and cooling effects in another section, thereby promoting convective air flow through the housing 11 . Likewise, housing 11 may be a lighter color throughout to minimize solar heating by solar radiation. In alternate embodiments convective flow through housing 11 may be induced or facilitated by a heater resistor. It will be appreciated that the dimensions and characteristics (e.g., color) may be incorporated, and/or accounted for by controller 19 discussed herein.
[0033] Housing 11 also contains evaporation controller 14 . Evaporation controller 14 exerts pressure on wick 17 at point 17 A which controls the flow of moisture from reservoir 15 , along wick 17 , through evaporation controller 14 to be evaporated into the interior chamber 11 A of housing 11 . It will be appreciated that evaporation controller 14 works cooperatively with the characteristics of wick 17 to control the evaporation into the interior of housing 11 . For example the pick dimension P, or Picks per inch—is the number of carrier crossing points per longitudinal inch of wick 17 . Pick dimension P may be any suitable pick dimension, such as, for example, 2 carrier crossings per inch.
[0034] Still referring to FIG. 1 , the water reserve 151 may be extended (e.g. less evaporation to the ambient air, by minimizing the length of wick 17 exposed to air. This can be done with placement of the reservoir 15 relative to the wick 17 and/or with a covering or sleeve 502 over the wick 17 . For clarity only a partial covering 502 is shown.
[0035] Still referring to FIG. 1 , reservoir container 15 may be any suitable container for holding liquid 151 (e.g. water). In alternate embodiments reservoir container 15 may also include sensor 16 . Sensor 16 may communicate reservoir status to controller 19 . For example status may include liquid level, temperature, or viscosity. Also shown in FIG. 1 is reservoir heater 15 A. Reservoir heater may be any suitable heater such as for example, electric or solar and may be thermostatically controlled. Similarly reservoir 15 may be painted or otherwise colorized any suitable color for absorbing or reflecting sunlight or any other radiant light in order to adjust the temperature of the liquid 151 held in reservoir 15 .
[0036] Also shown in FIG. 1 is controller 19 . Controller 19 comprises: memory or computer readable medium 19 B, at least one processor or programmable controller 19 A, analog-to-digital and digital-to-analog converters necessary to process information relayed from sensors 12 and 13 via standard input/output channels or wireless connections; and, if present, from sensor 16 . Controller 19 computes the relative humidity (RH) for display on display readout 191 . It will be appreciated that RH may be computed by controller 19 according to equation 1 and equation 2 discussed earlier; or, any suitable algorithm for determining RH based upon wet and dry bulb temperatures. In alternate embodiments a secondary input of barometric pressure can be included to more accurately calculate saturation, however in mathematical modeling the impact of pressure is generally negligible in RH calculation.
[0037] FIG. 1 also shows connectors 18 and 161 for transmitting sensor data from housing 11 and container 15 , respectively. It will be appreciated that connectors 18 and/or 161 may be any suitable connector including wireless.
[0038] Referring also to FIG. 2 there is shown a pictorial illustration of a self-ventilating and adjustable ventilation cover plate 20 in accordance with the invention shown in FIG. 1 . Ventilation cover plate 20 includes cover 21 and ventilation cavities 22 . Cover plate 21 is suitably sized and shaped to enclosed housing 11 interior chamber 11 A. Ventilation cavities 22 may be any suitable size, number, and shape to cooperatively work with evaporation controller 14 and wick 17 to control the evaporation of liquid 151 into the interior chamber 11 A of housing 11 .
[0039] Referring also to FIG. 3 there is shown a pictorial illustration of a system of psychrometer systems in accordance with the invention shown in FIG. 1 . It will be understood that any suitable number of enclosed psychrometers 10 may be distributed in a space. Each of the psychrometers is suitably connected to controller 19 via a suitable connector, e.g., wire or wireless. Controller 19 monitors and determines the RH value for each station and displays on display 191 . It will also be understood that controller 19 includes the logic and circuitry necessary to display warnings and or alarms if the RH for any given station is not within a specified range; or, if the liquid at each station is below a predetermined level. Alarms may be any suitable combination of visual or audio alarms. In addition, alarms may be communicated over an internet or cellular connection. It will be appreciated that any suitable configuration may be employed. For example, a configuration where each sensor has the required controller 19 to conduct the RH calculation and sends data, via a wireless connection or hardline, to a main controller which handles output controls. The alarm signal may also include the logic and resources necessary to drive humidifiers and/or dehumidifiers ( 400 ) to bring relative humidity to non-alarm levels.
[0040] Referring also to FIG. 4 there is shown an illustration of one method 40 for calibrating the wet/dry thermistors in accordance with the invention shown in FIG. 1 . It will be appreciated that synchronous calibration of the wet-bulb and dry-bulb temperature sensors is critical to accuracy. The first step 45 immerses the wet/dry sensors in reference fluid with a known temperature, such as for example, a stirred ice bath at 0 C (32 F). It will be appreciated that any suitable reference fluid may be used, such as, for example, a 100 degree C. boiling bath for applications requiring high temperature accuracy. The processor ( FIG. 1-19B ) monitors the temperatures reported by the wet/dry sensors periodically, e.g., every second 42 for ten seconds, for example. If the variance of the array of temperature readings is less than a predetermined amount 44 the processor 19 B determines 46 the calibration temperature offset (from the reference fluid temperature) for each wet/dry sensor. The processor 19 B saves the calibration offset for each wet/dry sensor in non-volatile memory 19 A. Otherwise, if the variance is greater than the predetermined amount another array of temperature values is measured 42 . It will be appreciated that calibration of the temperature sensors as described overcomes two prior art problems. First, manufacturer tolerance on temperature vs. resistance for thermistors (or other sensors) is generally rated at 20 or 25 C, not 0 C resulting in drift in the desired measurement regime. In addition, there is often integration resistance deviation when attaching the sensors or When using wire for remote placement of the sensors.
Prototype Description
[0041] A prototype utilized two NTC 10 k Ohm thermistors in a voltage dividing circuit with a fixed 10 k Ohm resistor. With reasonable calibration (see FIG. 4 ), the temperature of a thermistor changes its resistance in a predictably precise and accurate manner. Using the voltage dividing circuit, this resistance is indirectly measured by the voltage across the fixed resistor. An Arduino Uno microcontroller supplied 5 VDC +/− voltage to the voltage dividers and measured the circuit voltage using a 10-bit analog to digital converter. In this prototype the Arduino Uno microcontroller software assumed 5 VDC for calculating resistance of the thermistors, however an alternate embodiment measures the bus voltage and incorporates this into the calculation to reduce error. One of the thermistors is referenced to air directly to measure dry bulb temperature. The other is wrapped in a wick used for manual sling psychrometers with the far end of the wick placed in a reservoir of water to saturate the wick remotely. This sensor measures wet bulb temperatures. In prototype experiments it was expected that air flow over the wet bulb thermistor would be required, similar to the need for swinging a manual psychrometer. However, it was noted in the first experiment that this was not needed since the thermal mass of the thermistor is considerably less than that of a traditional liquid thermometer and its fluid in the manual sling psychrometer; and, thus requires lower heat transfer rates to reach equilibrium at the wet bulb temperature. The coarseness and other characteristics of the wick are also important in this design element; the wick used initially was quite open and loose allowing for good evaporation and air flow dose to the measurement surface. Regardless, the behavior was repeated and is predictable.
INITIAL RESULTS
[0042] FIRST PROTOTYPE—Using high precision thermistors a prototype circuit and associated software was developed to measure dry bulb and wet bulb temperatures. The prototype thermistors are mounted on a breadboard, but would eventually be mounted remotely from the main circuit, connected with wire or wireless connections. Thermistors can be made to be moisture resistant with potting (epoxy) and can also be manufactured to very high precision (+/−0.1 deg. F). The measurement approach used in this design should result in a more rugged, precise, and accurate measurement of RH in low temperature high humidity environments at a material cost under $50.
[0043] SECOND PROTOTYPE (See FIG. 1 )—A remote housing 11 having two openings was provided. A rubber stopper was used to plug one of the conduit holes and to allow CAT5e cabling to enter the housing. The evaporation controller 14 was glued into the other opening allowing the connection of the water reservoir 15 and a controlled, wick water supply 151 with minimal evaporation from the bottle. Various size bottles can be used, this prototype used a 1 fl oz size.
[0044] High accuracy NTC thermistors were used in the second prototype (10 kOhm +/−0.05 deg. C. US Sensor · PR103J2), No other significant changes were made to the circuit in this build. In initial tests of this build, it was found that an optional air flow over the wet-bulb thermistor could be used to stably depress the wet-bulb temperature. A small fan (Orion # OD2510-05HB) was integrated with desired results. The fan can be powered by any suitable means, e.g., battery power, solar powered, etc.
[0045] The prototypes used standard 10 k Ohm fixed resistors in the voltage divider. The actual resistance of the resistors was measured and used in the software-based calculation, but higher precision resistors would provide a more accurate RH calculation. Matching of the fixed resistors to the expected resistance of the thermistors in the measurement range results in maximum precision of the instrument.
[0046] The prototype or proof of concept used a laptop computer and USB connection for power and logging of results. A local LCD screen and power source were integrated into the prototype design. Other options for reporting sensor data are available for uploading data to cloud based data programs (Mojyle, etc.), email via Ethernet, or direct SMS text message communication via cell.
[0047] The prototype uses an Arduino Uno 10 bit analog to digital convertor which results in an output precision of about 0.09%. It will be appreciated that higher bit convertors would result in higher precision.
[0048] Referring to the figures it will be appreciated that item 400 ( FIG. 3 ) represents a controlled device, such as, for example, a humidifier, a dehumidifier, a fan, or the like. It will be understood that devices such as the aforementioned may be controlled by controller 19 according to the calculated RH levels. There are currently no low temperature, high humidity humidistats on the market that are suitable for these applications. The microcontroller 19 may be programmed to provide control of such a system resulting in a very precise and stable control system for RH in storage.
[0049] It should be understood that the foregoing description is only illustrative of the invention. Thus, various alternatives and modifications can be devised by those skilled in the art without departing from the invention.
[0050] For example, enclosure of the sensing probes with careful attention to aspiration helps to avoid erratic readings during a compressor cycle in the refrigeration system. When the compressor runs, the air coming off an evaporator in a cooler will be very cold and very dry which may drive the dry bulb temperature lower very quickly. The wet-bulb is enclosed in a moistened wick and takes longer to respond. This results in an RH inversion which sends it above 100% (not possible). In an alternate embodiment a piece of dry wick material, same material as the wet-bulb, may be used to cover the dry bulb to make their dynamic thermal response relatively more equal. The other is using the enclosure lid. Alternatively, software processing by processor 19 B may identify the situation and disregard the data and/or annotate the data stream to clarify it.
[0051] Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances that fall within the scope a the appended claims. | The present invention has to do with a method and system for a high precision electronic psychrometer operable at low temperatures and high humidity environments. The electronic psychrometer includes thermistors for measuring wet and dry bulb temperatures and a wicked cage surrounding one of the thermistors. The wicking action of the wicked cage is controlled by an evaporation controller in conjunction with the wick's physical parameters. The electronic psychrometer determines relative humidity and provides a readout display and/or a control signal. | 6 |
BACKGROUND OF INVENTION
1. Field of the Invention
This invention relates to a seam for joining together the ends of woven fabric to form an endless belt. It is applicable more specifically to joining the ends of woven synthetic dryer fabrics as used in the dryer section of paper making machines and is particularly applicable to joining the ends of those dryer fabrics which have very pliable or multifilament yarns in at least the machine direction of the fabric.
2. Description of Prior Art
Dryer fabrics are usually woven of natural or synethethic fibres such as, for example, polyesters, nylons, acrylics, bulked or of interwoven layered structure to produce a heavy woven fabric which can be, for example, from about 1/32 to about 1/8 of an inch thick. Dryer fabrics are supplied in various widths from about 5 feet to about 30 feet depending on the width of the paper machine, and in length from about 40 feet to about 350 feet.
It is common practice to weave the dryer fabric as a long wide flat single piece and then join the ends on the machine to make an endless belt. There are several known methods of making the joint or seam as it is called. In one method, each end of the fabric is provided with a set of metal clipper type loops. In another method, metal or plastic loops are sewn into the ends which have been reinforced to prevent unravelling. In still another method, cross machine strands(weft) are removed near the ends of the fabric and the ends are folded back in such a way that warp loops in the unwefted sections project. In each case the joint is completed when the array of loops at one end is intermeshed with the array of loops at the other end and brought into register to form a tubular passage through which a hinge pin or pintle wire is inserted.
These above known conventional methods of making a seam in heavy dryer fabrics all have the disadvantage of either producing a gross lump which causes sheet disturbance and marking or an almost complete mesh blockage. Either of these features being objectional from the point of view of fabric wear or quality of sheet.
Another type of seam that has been successfully used in dryer fabrics having monofilament longitudinal strands capable of retaining a stable crimp is a loop type wherein the loops are formed at each end edge in the following manner. Projecting longitudinal (machine direction) strands from which cross strands have been removed at each end of the fabric are interwoven again into a plurality of added cross strands comprising either the removed or similarly crimped strands in the seam area. Selected longitudinal strands are looped over a forming rod at the end edge of the plurality of added cross strands and are woven back into the added cross strands to meet the ends of adjacent machine direction strands which have been woven part way into the group of added cross strands and terminated. The surplus ends of these longitudinal strands are subsequently clipped off at the surface of the cloth in the seam area where they meet to form abutting terminations. Those longitudinal strands that are not looped over the forming rod are simply looped tightly over the last added cross strand and similarly woven back into the seam area to meet an adjacent longitudinal strand at an abutting termination. Abutting termination points of the longitudinal strands are positioned in a predetermined uniform pattern throughout the seam area to avoid having them clustered together where they might obstruct the mesh unduly or cause a surface lump or a weakness of tensile strength in the joint.
A forming rod is looped in as described above at each end of the fabric and when it is required to join the ends of the fabric on the paper machine, the forming rods are withdrawn, the loops are intermeshed and the hinge pin (pintle wire) is inserted.
The advantage of this type of seam is that the continuity of mesh at each end, right up to the formed loops, is maintained without a layered thickening and without a discernible mesh blockage. The success of making such a seam depends upon stability of crimp in the longitudinal strands. The strength of the seam is controllable and determined by the number and strength of the looped longitudinal strands and by the number of added cross strands through which the crimped longitudinal strands are interwoven.
While this type of seam is ideal for joining the ends of dryer fabrics having monofilament longitudinal strands capable of retaining a crimp, it has not been possible to apply the method to dryer fabrics having, for example, multifilament longitudinal strands, which are generally pliable and do not have a stable cross-sectional dimension and crimp, although many attempts have been made to seam them in this way because of the physical and economic advantages which the multifilament strands offer.
The multifilament strands are generally made up of a large number of single fibers of very small diameter, twisted together to form a single flexible strand. Since these strands are normally quite limp the fabric made from them is generally coated with a thermo-setting resin material to stiffen it so that it will resist distortion in its own plane. While the coating of resin material does tend to make the multifilament strands less pliable it is generally only effective in this respect in the woven state and once disturbed, as when the strands are unwoven, the coating comes off and they again become pliable.
The problem encountered when attempting to seam fabrics comprising longitudinal multifilament or other strands incapable of holding a crimp is that the crimp is not stable after a strand is unwoven and it does not assume exactly the same configuration when re-woven in the seam area, thus the spacing of both the added cross strands and the longitudinal strands is affected. Multifilament strands tend to splay out and become bulky as well as limp and attempts to force them into place when re-weaving causes the seam area to become lumpy. Also, a point is soon reached, after weaving a number of multifilament strands, when it is impossible to force any more strands into the mesh. Attempts to alleviate this condition by cutting out say every 3rd, 4th or 5th multifilament strand reduces the lumpy effect to some extent but does not contribute to retention of uniform spacing of the additional cross machine strands and so the advantage of cutting out some of the longitudinal strands is lost. Further, limp longitudinal strands do not retain crimp sufficiently well to lock them into the added cross strands, through which they are interwoven and they tend to pull out of the mesh, thus weakening the seam.
SUMMARY OF INVENTION
The main feature of the present invention is to overcome the above-mentioned objectional conditions, encountered when attempting to join multifilament fabrics, or fabrics having longitudinal strands which do not hold a crimp, with a woven-back pin type seam, by substituting monofilament strands having stable crimp characteristics and having substantially the same size and woven crimp configuration, for some of the longitudinal strands in the seam area and particularly for those that would be used to form loops over the forming rod. In this way, because of the rigid crimps and compact nature of the monofilament replacement strands, all the cross machine and longitudinal strands in the seam area are able to assume the normal spacing of the corresponding strands in the fabric and the re-weaving in the seam area is accomplished without difficulty.
The main advantage of the inventive method of replacing, for example, some of the multifilament strands in the seam area with monofilament strands is that heavy dryer fabrics, woven with multifilament longitudinal strands for the sake of flexibility and economy, may now be joined as easily and with the same desirable properties as those dryer fabrics woven with monofilament longitudinal strands.
A further advantage of this invention is that it may be employed regardless of the complexity of the mesh pattern and it is therefore suitable for the double or triple layer meshes often employed in the weaving of many dryer fabrics.
A further feature of the invention resides in the fact that the method of replacing strands, in the seam area, which do not hold a crimp with monofilament strands capable of holding a crimp, may be used to make a factory joined seam as described in British Pat. No. 1,264,818 in which the two ends of the fabric are woven together with added cross strands to form an endless belt without a pintle wire.
In some cases where, for one reason or another, one type of material, having specific deficiency, is used for weaving the fabric, another type of material possessing a property lacking in the strands of the fabric, may be used for the replacement monofilament strands of the seam. An example of this would be the use of nylon for the replacement strands because of its known greater resistance to abrasion in spite of it having other properties that would make it unsuitable for use in the body of the fabric which may normally comprise polyester strands which are generally more stable than nylon in a moist environment.
In other cases, for example, it may be appropriate to use crimped replacement strands of metal such as stainless steel or metal coated with plastic material to provide added protection against corrosion.
According to the above features, from a broad aspect, the present invention provides a woven fabric as used for supporting a paper web on a paper making machine. The fabric has interwoven weft and wrap strands with the strands in the machine direction being flexible strands incapable of retaining a stable crimp. The improvement in the fabric comprises a plurality of spaced apart replacement monofilament strands having stable crimp characteristics extending in the machine direction and in a seam area for interconnecting opposed ends of the fabric to form an endless belt having a seam which is substantially flat. The replacement strands have crimps of the same configuration as crimps in the machine direction strands of the fabric.
According to a further broad aspect, there is provided a method of forming a seam in a paper machine fabric having interwoven weft and warp strands; the strands in at least the machine direction being flexible strands incapable of retaining a stable crimp, said method comprising: (i) removing a plurality of cross machine strands from an area in opposed end edge portions of said fabric, (ii) crimping a plurality of monofilament strands having stable crimp characteristics with a crimp identical to that in the strands of the fabric in said machine direction, (iii) substituting a plurality of said monofilament strands in said machine direction for at least some of the machine direction strands in the said opposed end edge portions, and (iv) interweaving said machine direction fabric strands and said monofilament strands in said machine direction with a plurality of said removed cross machine strands, or cross machine strands taken from identical fabric, to form a seam area.
BRIEF DESCRIPTION OF DRAWINGS
The invention will now be described with reference to the accompanying drawings in which:
FIG. 1 is a partial plan view of a prepared end portion of a plain woven fabric having multifilament longitudinal yarns;
FIG. 2 is a partial plan view of the loop seam, with the loops intermeshed and joined with a hinge pin;
FIGS. 3a and 3b show a partial plan view and end elevation respectively, of a two pintle loop type seam in semi-twill fabric; and
FIG. 4 is a partial plan view illustrating a factory made seam joining the ends of a plain woven fabric having multifilament longitudinal yarns.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1, there is shown an end portion 30 of a woven fabric belt of a type used in the dryer section of a paper making machine. For the sake of simplicity, a plain woven pattern is shown; it being understood that any other known pattern in the art of weaving paper making fabrics may be used. Numerals 15a, 15b, 15c, etc., designate multifilament longitudinal or machine direction strands (warp) of the one end of the fabric. Strands 16a, 16b, 16c, etc., are the cross machine strands (weft) of the fabric. A number of weft strands were previously removed from the end of the fabric leaving unwoven warp strands 17a, 17b, 17c, 17d, etc., which are continuations of fabric warp strands 15a, 15b, 15c, etc., projecting from the fabric. Added weft strands 14a, 14b, 14c, . . . 14n are the same strands that were previously removed, or are identical to the weft strands of the fabric from which the weft strands were removed. For the pattern of the seam end shown in FIG. 1, pairs of projecting warp strands 15c and d and 15g and h etc., were cut off short and alternate pairs 15a and b and 15e and f, etc., were left long. Then, one of each pair of long projecting strands, 15b , 15f, etc. is woven through the added weft strands 14a, 14b, 14c, etc., looped firmly around the last added weft strand, 14n, and woven back into the added weft strands towards the other of each pair, 15a, 15e, etc. which is woven partially through the plurality of added weft strands. These strands meet in the seam area between two added weft strands and are cut to terminate at X so that the cut ends lie adjacent to one another. The termination points of each pair of long projecting longitudinal strands, so woven, are placed in a staggered pattern symmetrically in the seam area so that they do not all lie between the same two added cross strands. The purpose of the series of short loops thus formed is to hold the last added weft strand, 14n, in place.
Where the pairs of short cut longitudinal strands occur, shown at 15c and d, 15g and h, etc. monofilament strands 19, having the equivalent diameter and substantially the same crimp as the longitudinal multifilament strands are woven from points Y, at the termination of 15c, 15g, 15k, etc., through the added cross strands, are looped around a forming rod 20 to form long loops 21 and are woven back through the added strands to meet the adjacent longitudinal multifilament strands 15d, 15h, 15l, etc. at points Z. These replacement monofilament strands 19 take the place of certain of the multifilament strands and form the loops 21 of a hinge type connection. The termination points of the multifilament and monofilament strands, where they come together at Y and Z in the seam area, are also placed in a staggered pattern to reduce the possibility of forming a massive mesh blockage, a lump on the surface of the seam area or a weakness in the seam.
The other or second end of the fabric is prepared with monofilament loops woven into added cross strands in exactly the same manner. The long and short loops may be displaced laterally by one pair in the second end so that, when the long loops at each end are intermeshed to form the tubular passage through which the pintle wire is inserted, the longitudinal strands at one end of the fabric will line up with the corresponding longitudinal strands at the other end of the fabric.
While alternate pairs of the multifilament longitudinal strands are shown in FIG. 1 as being replaced by monofilament looped strands, a similar seam, using the concept of the invention, may be made where parts of all or any number of the multifilament longitudinal strands in the seam area may be replaced by monofilament strands of the same size and crimp configuration.
FIG. 2 shows the two end portions 30 and 31 of a fabric, prepared according to FIG. 1 and brought together. The forming rods have been removed and the monofilament loops 21 of the end edge of end portion 30 have been intermeshed with the monofilament loops 22 of the end edge of end portion 31. The hinge pin or pintle wire member 23 has been inserted through the intermeshed loops to hold the ends of the fabric together.
In some cases in order that replacement monofilament strands may be woven back in proper crimp sequence, certain of the loops will be formed longer than others. In semi-twill mesh pattern, for example, as shown in FIGS. 3a and 3b, when the first of every three consecutive longitudinal multifilament strands is woven around the last added cross strand and the two remaining strands are replaced by monofilament strands to form loops, it will be found that the crimps of the monofilament strands will fit better into the mesh if the loop of one of the remaining strands is made longer than the loop of the other. In cases like this where there are alternate long and short loops, the seam may be joined with two pintle wires as shown in FIGS. 3a and 3b.
Again, in some cases in which a hinge type seam is to be made in fabric having a complicated weave pattern in which a small number of the longitudinal strands have a crimp contour which is not symmetrical and is distinctive from the crimp contour of the rest of the strands which constitute the majority, it may happen that the asymmetrical strands will not fall in place in the mesh when attempts are made to weave them back into the cloth. In such cases, if it is not possible to fit the crimps in easily, even by twisting the strands about their own axes, it is permissible to simply eliminate them from the seam area by cutting them off at the end edges.
Although particularly suitable for making pin type seams in fabrics that are to be joined after installation on the paper machine, the method of this invention may also be used for making substantially flat seams in factory joined endless paper machine fabrics having longitudinal strands incapable of retaining a crimp. FIG. 4 shows a portion of a factory joined seam in which the two ends 3 and 4 of a multifilament fabric 1 are woven together with added crimped across strands 4a, 4b, 4c, etc., in a seam area 2 and in which, according to the present invention, some of the longitudinal multifilament strands 5a, 5b, 5c, etc., in the seam area are replaced by monofilament strands 6a, 6b, 6c, etc., which have about the same diameter and substantially the same crimp configuration as the longitudinal multifilament strands of the fabric.
In another embodiment of the invention in which greater flexibility of the seam area is required and, at the same time, it may be desirable to restrict drainage in the seam area, it has been found practical to use two or more slightly smaller monofilament strands instead of single larger diameter monofilament strands for replacing multifilament longitudinal strands in the seam area. This modification can be adapted to either the looped woven seam of FIG. 1 or the factory woven seam of FIG. 4.
It will be understood by those skilled in the art of weaving in this manner at the ends of woven fabric to make endless fabric belts that while the strength of the seam depends on the number of added cross strands and the type and mesh of the fabric, the added cross strands should be kept to a minimum for the sake of economy. For example, in a woven loop seam made according to the invention and as shown in FIG. 1, the number of added cross strands for a typical dryer fabric of any woven pattern will vary from about 30 to about 100 at each end edge. In the case of a factory woven seam as shown in FIG. 4, the number of added cross strands between the ends of the fabric will vary from about 60 to about 200. The extent of the seam area will, of course, be taken into account in the preparation of the ends of fabric to be joined so that, when seamed, the total length of the fabric will be as required.
Following re-weaving in the seam area according to this invention, it is considered advisable to restore the rigidity of the fabric in the seam area by re-coating with the same thermo-setting resin material that was used to stiffen the fabric originally.
The monofilament replacement strands are crimped by any well known method in the art. Also, the interweaving of the seam area, with the strands as disclosed herein, is done in a manner well known in the art and not disclosed herein as it does not form part of the present invention. | A woven fabric and a method of forming a seam therein comprising a woven fabric as used for supporting a paper web on a paper making machine. The fabric has interwoven weft and warp strands with the strands in the machine direction being flexible strands incapable of retaining a stable crimp. The improvement in the fabric comprises a plurality of spaced apart replacement monofilament strands having stable crimp characteristics extending in the machine direction and in a seam area for interconnecting opposed ends of the fabric to form an endless belt having a seam which is substantially flat. The replacement strands have crimps of the same configuration as crimps in the machine direction strands of the fabric. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Division of pending U.S. patent application Ser. No. 10/430,734 “Loaded Transducer for Downhole Drilling Components” filed on May 6, 2003, by David R. Hall, et al, and incorporated by reference herein for all it discloses.
STATEMENT OF GOVERNMENT INTEREST
[0002] This invention was made with government support under Contract No. DE-FC26-01NT41229 awarded by the U.S. Department of Energy. The government has certain rights in the invention.
BACKGROUND OF THE INVENTION
[0003] 1. The Field of the Invention
[0004] This invention relates to oil and gas drilling, and more particularly to apparatus and methods for reliably transmitting information between downhole drilling components.
[0005] 2. The Relevant Art
[0006] For the past several decades, engineers have worked to develop apparatus and methods to effectively transmit information from components located downhole on oil and gas drilling strings to the ground's surface. Part of the difficulty of this problem lies in the development of reliable apparatus and methods for transmitting information from one drill string component to another, such as between sections of drill pipe. The goal is to provide reliable information transmission between downhole components stretching thousands of feet beneath the earth's surface, while withstanding hostile wear and tear of subterranean conditions.
[0007] In an effort to provide solutions to this problem, engineers have developed a technology known as mud pulse telemetry. Rather than using electrical connections, mud pulse telemetry transmits information in the form of pressure pulses through fluids circulating through a well bore. However, data rates of mud pulse telemetry are very slow compared to data bandwidths needed to provide real-time data from downhole components.
[0008] For example, mud pulse telemetry systems often operate at data rates less than 10 bits per second. At this rate, data resolution is so poor that a driller is unable to make crucial decisions in real time. Since drilling equipment is often rented and very expensive, even slight mistakes incur substantial expense. Part of the expense can be attributed to time-consuming operations that are required to retrieve downhole data or to verify low-resolution data transmitted to the surface by mud pulse telemetry. Often, drilling or other procedures are halted while crucial data is gathered.
[0009] In an effort to overcome limitations imposed by mud pulse telemetry systems, reliable connections are needed to transmit information between components in a drill string. For example, since direct electrical connections between drill string components may be impractical and unreliable, converting electrical signals to magnetic fields for later conversion back to electrical signals offers one solution for transmitting information between drill string components.
[0010] Nevertheless, various factors or problems may make data transmission unreliable. For example, dirt, rocks, mud, fluids, or other substances present when drilling may interfere with signals transmitted between components in a drill string. In other instances, gaps present between mating surfaces of drill string components may adversely affect the transmission of data therebetween.
[0011] Moreover, the harsh working environment of drill string components may cause damage to data transmission elements. Furthermore, since many drill string components are located beneath the surface of the ground, replacing or servicing data transmission components may be costly, impractical, or impossible. Thus, robust and environmentally-hardened data transmission components are needed to transmit information between drill string components.
SUMMARY OF THE INVENTION
[0012] In view of the foregoing, it is a primary object of the present invention to provide robust transmission elements for transmitting information between downhole tools, such as sections of drill pipe, in the presence of hostile environmental conditions, such as heat, dirt, rocks, mud, fluids, lubricants, and the like. It is a further object of the invention to maintain reliable connectivity between transmission elements to provide an uninterrupted flow of information between drill string components.
[0013] Consistent with the foregoing objects, and in accordance with the invention as embodied and broadly described herein, an apparatus is disclosed in one embodiment of the present invention as including a transmission element having a communicating surface mountable proximate a mating surface of a downhole drilling component, such as a section of drill pipe.
[0014] By “mating surface,” it is meant a surface on a downhole component intended to contact or nearly contact the surface of another downhole component, such as another section of drill pipe. For example, a mating surface may include threaded regions of a box end or pin end of drill pipe, primary or secondary shoulders designed to come into contact with one another, or other surfaces of downhole components that are intended to contact or come into close proximity to surfaces of other downhole components.
[0015] A transmission element may be configured to communicate with a corresponding transmission element located on another downhole component. The corresponding transmission element may likewise be mountable proximate a mating surface of the corresponding downhole component. In order to close gaps present between communicating surfaces of transmission elements, transmission elements may be biased with respect to the mating surfaces they are mounted on.
[0016] By “biased,” it is meant, for the purposes of this specification, that a transmission element is urged, by a biasing member, such as a spring or an elastomeric material, or by a “spring force” caused by contact between a transmission element and a mating surface, in a direction substantially orthogonal to the mating surface. Thus, the term “biased” is not intended to denote a physical position of a transmission element with respect to a mating surface, but rather the condition of a transmission element being urged in a selected direction with respect to the mating surface. In selected embodiments, the transmission element may be positioned flush with, above, or below the mating surface.
[0017] Since a transmission element is intended to communicate with another transmission element mounted to another downhole tool, in selected embodiments, only a single transmission element is biased with respect to a mating surface. For example, transmission elements may be biased only in “pin ends” of downhole tools, but may be unbiased or fixed in “box ends” of the same downhole tools. However, in other embodiments, the transmission elements are biased in both the pin ends and box ends.
[0018] In selected embodiments, a gap may be present between mating surfaces of downhole tools due to variations in tolerances, or materials that may become interposed between the mating surfaces. In other embodiments, the mating surfaces are in contact with one another. In selected embodiments, a biasing member, such as a spring or elastomeric material may be inserted between a transmission element and a corresponding mating surface to effect a bias therebetween.
[0019] A mating surface may be shaped to include a recess. A transmission element may be mounted or housed within the recess. In selected embodiments, a recess may include a locking mechanism to retain the transmission element within the recess. In certain embodiments, the locking mechanism is a locking shoulder shaped into the recess. A transmission element, once inserted into the recess, may slip past and be retained by the locking shoulder.
[0020] A transmission element and corresponding recess may have an annular shape. In selected embodiments, a transmission element may snap into the recess and be retained by the locking mechanism. In selected embodiments, angled surfaces of the recess and the transmission element may create a “spring force” urging the transmission element in a direction substantially orthogonal to the mating surface. This “spring force” may be caused by the contact of various surfaces of the transmission element and the recess, including the outside diameters, the inside diameters, or a combination thereof.
[0021] In selected embodiments, a transmission element on a downhole component communicates with a transmission element on a separate downhole component by converting an electrical signal to a magnetic field or current. The magnetic field or current induces an electrical current in a corresponding transmission element, thereby recreating the original electrical signal. In other embodiments, a transmission element located on a downhole component may communicate with a transmission element on another downhole component due to direct electrical contact therebetween.
[0022] In another aspect of the present invention, a method for transmitting information between downhole tools located on a drill string includes mounting a transmission element, having a communicating surface, proximate a mating surface of a downhole tool. Another transmission element, having a communicating surface, may be mounted proximate a mating surface of another downhole tool, the mating surfaces of each downhole tool being configured to contact one another. The method may further include biasing at least one transmission element with respect to a corresponding mating surface to close gaps present between communicating surfaces of the transmission elements.
[0023] In certain instances, a gap may be present between the mating surfaces. In other instances, mating surfaces may be in direct contact with one another. The method may further include providing a biasing member, such as a spring, elastomeric material, or the like, to effect the bias between a transmission element and a mating surface.
[0024] A method may further include shaping a mating surface to include a recess such that the transmission element substantially resides in the recess. Within the recess, a locking mechanism may be provided to retain the transmission element within the recess. The locking mechanism may be a locking shoulder and the transmission element may be retained within the first recess by slipping by and engaging the locking shoulder.
[0025] A method in accordance with the invention may further include forming a transmission element and a recess into an annular shape. Furthermore, biasing of the transmission element may be provided by angled surfaces of the recess and the transmission element to create a “spring force,” thereby urging the transmission element in a direction substantially orthogonal to a mating surface. This “spring force” may be caused by contact between various surfaces of the transmission element and the recess, including the outside diameters, the inside diameters, or a combination thereof. The method may further include communicating between transmission elements due to direct electrical contact or by transfer of magnetic energy therebetween.
[0026] In another aspect of the present invention, an apparatus for transmitting data between downhole tools may include a loaded annular housing. By “loaded,” it is meant, for the purposes of this specification, providing a “spring force” between a mating surface and an annular housing mounted thereon. In selected embodiments, the annular housing may include at least one substantially U-shaped element disposed within the loaded annular housing.
[0027] The U-shaped element may be composed of a magnetically conductive and electrically insulating material, such as ferrite, thereby enabling magnetic current to be retained therein and channeled in a desired direction. An electrical conductor may be disposed within the U-shaped element to carry electrical current. The electrical conductor may be electrically insulated to prevent shorting of the conductor to other electrically conductive components.
[0028] The loaded annular housing may be formed such that it is mountable in a recess of a mating surface of a downhole tool. The annular housing may be flush with the mating surface, below the mating surface, above the mating surface, or a combination thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The foregoing and other features of the present invention will become more fully apparent from the following description, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments in accordance with the invention and are, therefore, not to be considered limiting of its scope, the invention will be described with additional specificity and detail through use of the accompanying drawings in which:
[0030] FIG. 1 is a perspective view illustrating one embodiment of sections of downhole drilling pipe using transmission elements, in accordance with the invention, to transmit and receive information along a drill string;
[0031] FIG. 2 is a cross-sectional view illustrating one embodiment of gaps that may be present between a pin end and box end of downhole drilling components, thereby causing unreliable communication between transmission elements;
[0032] FIG. 3 is a perspective cross-sectional view illustrating one embodiment of an improved transmission element retained within a recess of a box end or pin end of a downhole drilling component;
[0033] FIG. 4A is a perspective cross-sectional view illustrating one embodiment of a shoulder formed along both the inside and outside diameters of a loaded annular transmission element;
[0034] FIG. 4B is a perspective cross-sectional view illustrating one embodiment of a shoulder formed along the inside diameter of a loaded annular transmission element; and
[0035] FIG. 4C is a perspective cross-sectional view illustrating one embodiment of a shoulder formed along the outside diameter of a loaded annular transmission element.
DETAILED DESCRIPTION OF THE INVENTION
[0036] It will be readily understood that the components of the present invention, as generally described and illustrated in the Figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of embodiments of apparatus and methods of the present invention, as represented in the Figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of various selected embodiments of the invention.
[0037] The illustrated embodiments of the invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. Those of ordinary skill in the art will, of course, appreciate that various modifications to the apparatus and methods described herein may easily be made without departing from the essential characteristics of the invention, as described in connection with the Figures. Thus, the following description of the Figures is intended only by way of example, and simply illustrates certain selected embodiments consistent with the invention as claimed herein.
[0038] Referring to FIG. 1 , drill pipes 10 a, 10 b, or other downhole tools 10 a, 10 b, may include a pin end 12 and a box end 14 to connect drill pipes 10 a, 10 b or other components 10 a, 10 b together. In certain embodiments, a pin end 12 may include an external threaded portion to engage an internal threaded portion of the box end 14 . When threading a pin end 12 into a corresponding box end 14 , various shoulders may engage one another to provide structural support to components connected in a drill string.
[0039] For example, a pin end 12 may include a primary shoulder 16 and a secondary shoulder 18 . Likewise, the box end 14 may include a corresponding primary shoulder 20 and secondary shoulder 22 . A primary shoulder 16 , 20 may be labeled as such to indicate that a primary shoulder 16 , 20 provides the majority of the structural support to a drill pipe 10 or downhole component 10 . Nevertheless, a secondary shoulder 18 may also engage a corresponding secondary shoulder 22 in the box end 14 , providing additional support or strength to drill pipes 10 or components 10 connected in series.
[0040] As was previously discussed, apparatus and methods are needed to transmit information along a string of connected drill pipes 10 or other components 10 . As such, one major issue is the transmission of information across joints where a pin end 12 connects to a box end 14 . In selected embodiments, a transmission element 24 a may be mounted proximate a mating surface 18 or shoulder 18 on a pin end 12 to communicate information to another transmission element 24 b located on a mating surface 22 or shoulder 22 of the box end 14 . Cables 27 a, 27 b, or other transmission medium 27 , may be operably connected to the transmission elements 24 a, 24 b to transmit information therefrom along components 10 a, 10 b.
[0041] In certain embodiments, a recess may be provided in the secondary shoulder 18 of the pin end 12 and in the secondary shoulder 22 of the box end 14 to house each of the transmission elements 24 a, 24 b. The transmission elements 24 a, 24 b may have an annular shape and be mounted around the radius of the drill pipe 10 . Since a secondary shoulder 18 may contact or come very close to a secondary shoulder 22 of a box end 14 , a transmission element 24 a may sit substantially flush with a secondary shoulder 18 on a pin end 12 . Likewise, a transmission element 24 b may sit substantially flush with a surface of a secondary shoulder 22 of a box end 14 .
[0042] In selected embodiments, a transmission element 24 a may communicate with a corresponding transmission element 24 b by direct electrical contact therewith. In other embodiments, the transmission element 24 a may convert an electrical signal to a magnetic flux or magnetic current. A corresponding transmission element 24 b, located proximate the transmission element 24 a, may detect the magnetic field or current. The magnetic field may induce an electrical current into the transmission element 24 b that may then be transmitted from the transmission element 24 b to the electrical cable 27 b located along the drill pipe 10 or downhole component 10 .
[0043] As was previously stated, a downhole drilling environment may adversely affect communication between transmission elements 24 a, 24 b located on successive drill string components 10 . For example, materials such as dirt, mud, rocks, lubricants, or other fluids, may inadvertently interfere with the contact or communication between transmission elements 24 a, 24 b. In other embodiments, gaps present between a secondary shoulder 18 on a pin end 12 and a secondary shoulder 22 on a box end 14 due to variations in component tolerances may interfere with communication between transmission elements 24 a, 24 b. Thus, apparatus and methods are needed to reliably overcome these as well as other obstacles.
[0044] Referring to FIG. 2 , for example, as was previously stated, a gap 28 may be present between the secondary shoulders 18 , 22 of the pin end 12 and box end 14 . This gap 28 may be the result of variations in manufacturing tolerances between different sections 10 a, 10 b of pipe. In other embodiments, the gap 28 may be the result of materials such as dirt, rocks, mud, lubricants, fluids, or the like, interposed between the shoulders 18 , 22 .
[0045] If transmission elements 24 a, 24 b are designed for optimal function when in direct contact with one another, or when in close proximity to one another, materials or variations in tolerances leaving a gap 28 may cause malfunction of the transmission elements 24 a, 24 b, impeding or interfering with the flow of data. Thus, apparatus and methods are needed to improve reliability of communication between transmission elements 24 a, 24 b even in the presence of gaps 28 or other interfering substances.
[0046] In accordance with the present invention, a transmission element 24 a, 24 b may be provided such that it is moveable with respect to a corresponding shoulder 18 , 22 . Thus, transmission elements 24 a, 24 b may be translated such that they are in closer proximity to one another to enable effective communication therebetween. In selected embodiments, direct contact between transmission elements 24 a, 24 b may be required.
[0047] In other embodiments, only a specified separation may be allowed between transmission elements 24 a, 24 b for effective communication. As illustrated, transmission elements 24 a, 24 b may be mounted in secondary shoulders 18 , 22 of the pin end 12 and box end 14 respectively. In reality, the transmission elements 24 a, 24 b may be provided in any suitable surface of the pin end 12 and box end 14 , such as in primary shoulders 16 , 20 .
[0048] Referring to FIG. 3 , in selected embodiments, a transmission element 24 may include an annular housing 30 . The annular housing 30 may include a magnetically conducting electrically insulating element 32 therein, such as ferrite or some other material of similar electrical and magnetic properties. The element 32 a may be formed in a U-shape and fit within the housing 30 . Within the U-shaped element 32 a, a conductor 34 may be provided to carry electrical current therethrough. In selected embodiments, the electrical conductor 34 is coated with an electrically insulating material 36 .
[0049] As current flows through the conductor 34 , a magnetic flux or field may be created around the conductor 34 . The U-shaped element 32 may serve to contain the magnetic flux created by the conductor 34 and prevent energy leakage into surrounding materials. The U-shape of the element 32 may also serve to transfer magnetic current to a similarly shaped element 32 in another transmission element 24 . Since materials such as ferrite may be quite brittle, the U-shaped elements 32 may be provided in segments 32 a, 32 b to prevent cracking or breakage that might otherwise occur using a single piece of ferrite.
[0050] As was previously stated, a recess 38 may be provided in a mating surface 18 , such as in a secondary shoulder 18 . Likewise, the transmission element 24 may be inserted into and retained within the recess 38 . In selected embodiments, the recess 38 may include a locking mechanism to enable the housing 30 to enter the recess 38 while preventing the exit therefrom. For example, in one embodiment, a locking mechanism may simply be a groove 40 or recess 40 formed within the larger recess 38 . A corresponding shoulder 42 may be formed in the housing 30 such that the shoulder 42 engages the recess 40 , thereby preventing the housing 30 from exiting the larger recess 38 .
[0051] As was previously discussed, in order to close gaps 28 or space 28 present between transmission elements 24 a, 24 b, in the pin end 12 and box end 14 , respectively, a transmission element 24 may be biased with respect to a mating surface 18 , such as a secondary shoulder 18 . That is, a transmission element 24 may be urged in a direction 46 with respect to a secondary shoulder 18 . In selected embodiments, angled surfaces 50 , 52 of the recess 38 and housing 30 , respectively, may provide this “spring force” in the direction 46 .
[0052] For example, each of the surfaces 50 , 52 may form an angle 48 with respect to a direction normal or perpendicular to the surface 18 . This angle 48 may urge the housing 30 in a direction 46 due to its slope 48 . That is, if the housing 30 is in tension as it is pressed into the recess 38 , a spring-like force may urge the housing 30 in a direction 46 .
[0053] In other embodiments, a biasing member, such as a spring or other elastomeric material may be inserted between the housing 30 and the recess 38 , in a space 56 , to urge the housing 30 in a direction 46 . In selected embodiments, the housing 30 may only contact a single surface 50 of the recess 38 . Gaps 54 , 56 may be present between the recess 38 and the housing 30 along other surfaces. These may serve several purposes.
[0054] For example, if the housing 30 were to contact both a surface 50 on one side of the recess 38 , as well as another surface 54 on the other side of the recess 38 , pressure on both sides of the housing 30 may create undesired stress on a U-shaped element 32 or elements 32 a, 32 b. If an element 32 is constructed of ferrite, the stress may cause cracking or damage due to its brittleness. Thus, in selected embodiments, it may be desirable that only a single surface 50 of the housing 30 contact a surface 52 of the recess 38 .
[0055] Nevertheless, a surface 50 in contact with the housing 38 may be along either an inside or outside diameter of the recess 38 , or a combination thereof. Other recesses 44 a, 44 b, or spaces 44 a, 44 b, may be provided between the housing 30 and U-shaped elements 32 . These recesses 44 a, 44 b may be filled with an elastomeric or bonding material to help retain the U-shaped elements 32 within the housing 30 .
[0056] Referring to FIGS. 4A, 4B , and 4 C, while continuing to refer generally to FIG. 3 , a transmission element 24 may include one or several shoulders 42 to engage one or several locking recesses 40 within the larger recess 38 . For example, referring to FIG. 4A , a transmission element 24 may include multiple locking shoulders 42 a, 42 b along both an inner and outer diameter of a housing 30 . These shoulders 42 a, 42 b may interlock with corresponding grooves 40 or recesses 40 formed in the recess 38 .
[0057] In another embodiment, referring to FIG. 4B , a transmission element 24 may simply include a single locking shoulder 42 a located along an inside diameter of the transmission element 24 . This locking shoulder 42 a may engage a corresponding groove 40 or recess 40 located along the inside diameter of the larger recess 38 . Likewise, with respect to FIG. 4C , a transmission element 24 may simply include a locking shoulder around an outside diameter of the transmission element 24 . A corresponding groove 40 may be included around the outside diameter of the recess 38 to retain the transmission element 24 .
[0058] The present invention may be embodied in other specific forms without departing from its essence 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 within the meaning and range of equivalency of the claims are to be embraced within their scope. | A robust transmission element for transmitting information between downhole tools, such as sections of drill pipe, in the presence of hostile environmental conditions, such as heat, dirt, rocks, mud, fluids, lubricants, and the like. The transmission element maintains reliable connectivity between transmission elements, thereby providing an uninterrupted flow of information between drill string components. A transmission element is mounted within a recess proximate a mating surface of a downhole drilling component, such as a section of drill pipe. To close gaps present between transmission elements, transmission elements may be biased with a “spring force,” urging them closer together. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. application Ser. No. 11/128,229, filed on May 13, 2005; which is a continuation of U.S. application Ser. No. 10/998,015, filed on Nov. 29, 2004; which is a continuation of U.S. application Ser. No. 10/890,199, filed on Jul. 14, 2004; which is a continuation of U.S. application Ser. No. 09/552,564, filed on Apr. 19, 2000, now U.S. Pat. No. 6,842,459, issued: Jan. 11, 2005, the disclosures of which are incorporated herein by reference
FIELD OF THE INVENTION
The present invention relates to the field of communication networks, and, more specifically, to the networking of devices within a building via combined wired and non-wired communication.
BACKGROUND OF THE INVENTION
There is a growing need for networking within the home. This need is driven by two major factors, the increasing use of multiple data devices and the emergence of broadband services in the home.
Lately there has been an expansion in the number of homes in the USA with multiple personal computers. In addition, connectivity and networking capabilities have been added to appliances, such as refrigerators and microwave ovens. Furthermore, there is a trend toward enabling data connectivity among various multimedia (audio and video) appliances such as TV's, VCR's, receivers, and speakers. The term “data unit” as used herein denotes any device capable of generating and/or receiving data. The networking of data units enables the sharing of files and applications as well as the sharing of common peripheral devices, along with other benefits.
Another driving force behind the need for home connectivity products is the growth in the number of on-line households. As high-speed connections to information and broadband entertainment sources soar, there is a growing need to share and distribute this access among appliances within the house. These broadband services are supplied mainly by three types of service providers:
1. Telco's, via xDSL connections (currently ADSL, to be followed by VDSL). 2. CATV. Currently via Cable-Modem, to be followed by digital Set-Top-Box. 3. Wireless connections, such as Satellite, LMDS, WLL, and others.
Communication within a home can be classified into two types: wired and non-wired. These are covered below:
Wired Communication
Wired communication requires using at least two distinct electrical conductors. The wiring can be new wiring installed and dedicated for data communication within the home, such as installing structured wiring such as Category 5 type, used in Ethernet IEEE802 networks. However, the installation of a new wiring structure within a home is labor-intensive, complex, and expensive. Alternatively, existing home wiring, which was previously installed for a specific purpose, can be used for data communication without substantially affecting or degrading the original service. Existing wiring includes telephone wiring, power line wiring, and cable TV wiring. These are reviewed below.
For all wired configurations, the present invention relies upon electrically-conducting lines which may be pre-existing within a building, which have at least two distinct electrical conductors, and which are capable of transporting data communication signals. Furthermore, the present invention relies upon suitable outlets, to which the electrically-conducting lines are coupled, and which are capable of connecting to external devices.
Telephone Wiring
In-home telephone service usually employs two or four wires, and is accessed via telephone outlets into which the telephone sets are connected.
FIG. 1 shows the wiring configuration of a prior-art telephone system 10 for a residence or other building, wired with a telephone line 5 . Residence telephone line 5 consists of single wire pair which connects to a junction-box 16 , which in turn connects to a Public Switched Telephone Network (PSTN) 18 via a cable 17 , terminating in a public switch 19 , which establishes and enables telephony from one telephone to another. The term “analog telephony” as used herein denotes traditional analog low-frequency audio voice signals typically under 3 KHz, sometimes referred to as “POTS” (“Plain Old Telephone Service”), whereas the term “telephony” in general denotes any kind of telephone service, including digital service such as Integrated Services Digital Network (ISDN). The term “high-frequency” as used herein denotes any frequency substantially above such analog telephony audio frequencies, such as that used for data. ISDN typically uses frequencies not exceeding 100 KHz (typically the energy is concentrated around 40 Khz). The term “telephone line” as used herein denotes electrically-conducting lines which are intended primarily for the carrying and distribution of analog telephony, and includes, but is not limited to, such electrically-conducting lines which may be pre-existing within a building and which may currently provide analog telephony service. The term “telephone device” as used herein denotes, without limitation, any apparatus for telephony (including both analog telephony and ISDN), as well as any device using telephony signals, such as fax, voice-modem, and so forth.
Junction box 16 is used to separate the in-home circuitry from the PSTN and is used as a test facility for troubleshooting as well as for wiring new in the home. A plurality of telephones 13 a and 13 b connects to telephone lines 5 via a plurality of telephone outlets 11 a , 11 b , 11 c , and 11 d . Each outlet has a connector (often referred to as a “jack”), denoted in FIG. 1 as 12 a , 12 b , 12 c , and 12 d , respectively. In North-America, RJ-11 is commonly used. Each outlet may be connected to a telephone unit via a connector (often referred to as a “plug”), denoted in FIG. 1 (for the two telephone units 13 a and 13 b illustrated) as 14 a and 14 b , respectively. It is also important to note that lines 5 a , 5 b , 5 c , 5 d , and 5 e are electrically the same paired conductors.
While network 10 exhibits serial or daisy-chained topology wherein the wiring is serialized from an outlet the next one only, other topologies such as star, tree or any arbitrary topology may also exist. However, the telephone wiring system within a residence is always composed of wired media: two or four copper wires, and several outlets which provides direct access for connecting to these wires.
There is a requirement for simultaneously using the existing telephone infrastructure for both telephone and data networking. In this way, the task of establishing a new local area network in a home or other building is simplified, because there would be no additional wires to install. U.S. Pat. No. 4,766,402 to Crane (hereinafter referred to as “Crane”) teaches a way to form LAN over two-wire telephone lines, but without the telephone service.
As an another example, relevant prior-art in this field is disclosed in U.S. Pat. No. 5,896,443 to Dichter (hereinafter referred to as “Dichter”). Dichter suggests a method and apparatus for applying frequency domain/division multiplexing (FDM) technique for residential telephone wiring, enabling simultaneously carrying telephone and data communication signals. The bandwidth enabled by the wiring is split into a low-frequency band capable of carrying an analog telephony signal and a high-frequency band capable of carrying data communication signals. In such mechanism, the telephone service is not affected, while data communication capability is provided over existing telephone wiring within a home.
The concept of frequency domain/division multiplexing (FDM) is well-known in the art, and provides means of splitting the bandwidth carried by a wire into a low-frequency band capable of carrying an analog telephony signal and a high-frequency band capable of carrying data communication or other signals. Such a mechanism is described, for example, in U.S. Pat. No. 4,785,448 to Reichert et al. (hereinafter referred to as “Reichert”). Also widely used are xDSL systems, primarily Asymmetric Digital Subscriber Loop (ADSL) systems.
The Dichter network is illustrated in FIG. 2 , which shows a network 20 serving both telephones and providing a local area network of data units. Data Terminal Equipment (DTE) units 24 a , 24 b , and 24 c are connected to the local area network via Data Communication Equipment (DCE) units 23 a , 23 b , and 23 c , respectively. Examples of Data Communication Equipment include modems, line drivers, line receivers, and transceivers (the term “transceiver” herein denotes a combined transmitter and receiver). DCE units 23 a , 23 b , and 23 c are respectively connected to high pass filters (HPF) 22 a , 22 b , and 22 c . The HPF's allow the DCE units access to the high-frequency band carried by telephone-line 5 . In a first embodiment (not shown in FIG. 2 ), telephones 13 a , 13 b , and 13 c are directly connected to telephone line 5 via connectors 14 a , 14 b , and 14 c , respectively. However, in order to avoid interference to the data network caused by the telephones, in a second embodiment (shown in FIG. 2 ) low pass filters (LPF's) 21 a , 21 b , and 21 c are added to telephones 13 a , 13 b , and 13 c from telephone line 5 . Furthermore, a low pass filter is also connected to Junction Box 16 , in order to filter noises induced from or to the PSTN wiring 17 . It is important to note that lines 5 a , 5 b , 5 c , 5 d , and 5 e are electrically the same paired conductors.
Additional prior-art patents in this field can be found under US Class 379/093.08, which relates to carrying data over telephone wiring without any modifications made to the telephone wiring (e.g. wires and outlets). U.S. Pat. No. 5,841,360 and U.S. patent application Ser. Nos. 09/123,486 and 09/357,379 to the present inventor are the first to suggest modifying the telephone wiring, by means of splitting the wiring into distinct segments, each of which connects two telephone outlets. In this way, the network is modified from ‘bus’ topology into multiple ‘point-to-point’ segments, enabling superior communication characteristics.
Part of such a network 30 is shown in FIG. 3 , describing outlets 31 a and 31 b , substituting outlets 11 of FIGS. 1 and 2 . The telephone wiring 5 is split into distinct segments 5 a , 5 b and 5 c . Low-Pass Filter (LPF) and High-Pass Filters (HPF) are coupled to each wire segment end, in order to split between the telephony and the data signals. As shown in FIG. 3 , LPF's 21 b and 21 c are attached to each end of wiring segment 5 b . The LPF's are designed to allow passing of the telephony signals, and are connected together thus offering a continuous path for the telephony signals. Access to the telephony signals is made via connectors 12 a and 12 b in the outlets, into which telephone devices 13 a and 13 b are connected via connectors 14 a and 14 b respectively. Thus, the telephony service is fully retained. The data signals, carried in the high part of the spectrum, are accessed via HPF's 26 a and 22 b , coupled to each end of the telephone wire segment 5 b . HPF's 22 a and 26 b are connected to the ends of the wire segments 5 a and 5 c respectively. Each HPF is connected to a modem 23 and 27 , which transmit and receive data signals over the telephone wiring. Modems 23 a , 27 a , 23 b , and 27 b are connected to HPF's 22 a , 26 a , 22 b and 26 b respectively. Data units 24 a and 24 b are connected to the outlets 31 a and 31 b respectively, via a connector (not shown in the Figure) in the outlet. The data units are coupled via DTE interface in the outlet. Outlets 31 a and 31 b comprise DTE interfaces 29 a and 29 b respectively. The three data streams in each outlet, two from each modem and one from the DTE, are handled by an adapter 28 a and an adapter 28 b , which serve outlets 31 a and 31 b , respectively. While FIG. 3 describes an embodiment wherein all the components for the relevant functions are housed within the outlet, other embodiments are also possible, wherein only some of the components for these functions are contained within the outlet.
Power Lines
It is possible to transmit data over wiring used for distribution of electrical power within the home, which is normally at a frequency of 50 or 60 Hz. Access to the power is available via power outlets distributed around the house. Such wiring consists of two wires (phase and neutral) or three wires (phase, neutral, and ground).
FDM techniques, as well as others, are used for enabling data communication over power lines. Many prior-art patents in this field can be found in US Class 340/310.
Cable Television Lines
It is also possible to transmit data over wiring used for the distribution of television signals within the home. Such wiring usually is coaxial cable.
Both power line and cable television wiring systems resemble the telephone line structure described in FIG. 1 . The wiring system is based on conductors, usually located in the walls, and access to these wires is obtained via dedicated outlets, each housing a connector connected directly to the wires. Common to all these systems, is the fact that the wiring was installed for a dedicated purpose (telephone, power, or cable TV signal distribution). Wherever one of these existing wiring systems is used for carrying data, it is desirable that the original service (telephony, power, or television signal distribution) be unaffected. Dedicated modems are used for carrying data over the media concurrently with the original service.
When using existing wiring, specific wired modems are normally required for communicating over the electrically-conducting lines, and access to the electrically-conducting lines is provided via the relevant outlets. Using electrically-conducting lines as the communication media allows for high bandwidth, and provides robust and cost-effective communication. In addition, communication over large distances is possible, which in most cases enables coverage of the whole house, thereby guaranteeing communication from any outlet to another within the house.
Such networks, however, require data units to be connected to the outlets, usually by means of a cable from the data unit to a suitable nearby outlet. This makes the connection complex and hard-to-use, requires the data unit to be in proximity to an appropriate outlet, and impairs mobility for some data units within the house.
Non-Wired Communication
Non-wired solutions for in-home data networking use waves propagated without an electrically-conducting medium. Three main techniques are commonly used:
1. Radio Frequency (RF). Transmission of data between data units can be accomplished with radio frequency electromagnetic signals. As an example, IEEE802.11 can be used. 2. Light. Transmission of data between data units can be accomplished with light in the visible or non-visible spectrum. Currently, the most popular is infrared (IR) based communication. Most such systems require ‘line-of-sight’ placement of the communicating data units. 3. Sound. Transmission of data between data units can be accomplished with sound waves, either in the audio spectrum (20-20,000 Hz), or inaudible spectrum (ultrasonic, above 20,000 Hz; or infrasonic, below 20 Hz).
It is noted that although light and radio waves are both electromagnetic phenomena, they occupy different parts of the electromagnetic spectrum and have significantly different characteristics for purposes of the present invention. Thus, light and radio waves are herein treated as distinct physical phenomena.
An example of a non-wired data network 40 is shown in FIG. 4 . Two data units 41 a and 41 b are shown, into which non-wired transceivers 42 a and 42 b are respectively coupled. The non-wired transceivers 42 a and 42 b communicate over a space 43 without any electrically-conducting medium. If RF transmission is used, the transceivers are RF transceivers, and the communication over space 43 is based on the propagation of radio frequency electromagnetic waves. Similarly, in the case of light-based communication, transceivers 42 a and 42 b utilize light emitters (e.g. LEDs) and light detectors (e.g. photoelectric cell), and the communication over space 43 relies on the propagation of light. Likewise, in the case of sound-based communication over space 43 , the transceivers use microphones and speakers, and the communication relies on the propagation of sound waves through the air in the space 43 .
Since these solutions do not require any physical connection such as cable, they provide both ease-of-use and mobility. However, such non-wired solutions are effective over short distances only. Furthermore, most of the non-wired solutions cannot easily pass through walls and other such obstructions, owing to the attenuation to the signals. Hence, such techniques are suitable for communication within a single room, but are not suitable for communication between the rooms of a home or other building.
There is thus a widely recognized need for, and it would be highly advantageous to have, a means for implementing a data networking in-home between data units, wherein such data units can be networked within a home or other building, while providing mobility and ease of use. This goal is met by the present invention.
SUMMARY OF THE INVENTION
The present invention discloses a data communication network within a building having wired and non-wired segments. The wired segments are based on electrically-conducting lines installed within the building. In addition to supporting data communication, these electrically-conducting lines concurrently distribute a primary service other than the transport of data communication signals, such as telephone service, electrical power service, or cable television service, and may be pre-existing wires originally-installed to distribute the primary service. Dedicated outlets are used to enable direct access to the wiring. The present invention uses means for utilizing the electrically-conducting lines concurrently for both the transport of data communication signals and the primary service, without any interference between these two uses. The non-wired segments employ communication without electrically-conducting media, via waves propagated through open space, such as by light or radio waves, or by acoustic waves in air.
The wired and non-wired segments are combined by means of circuitry in one or more outlets. The coupling device is a module containing one port for coupling to the wired network using a specific wired modem. Another port of the device couples to the non-wired segment, using a non-wired modem. An adapter handles the data flow between the wired segment and the non-wired segment, and has provision for protocol conversion, if required.
The module coupling both segments, or any of the components of the module, can be fully integrated into the outlet, partially integrated into the outlet, or externally coupled to it.
Therefore, according to the present invention there is provided a local area network within a building for transporting data among a plurality of data units, the local area network including at least one wired segment and at least one non-wired segment, wherein the at least one wired segment includes: (a) at least one electrically-conducting line within the building, the electrically-conducting line having at least two conductors and operative to transport data communication signals; (b) at least two outlets, each operative for coupling to the electrically-conducting line; and (c) at least one wired modem coupled to the electrically-conducting line, operative to communicate over the electrically-conducting line; (d) and wherein the at least one non-wired segment is operative to communicating data without electrically-conducting media and includes at least one non-wired modem, wherein at least one of the outlets couples a wired segment to a non-wired segment, and wherein the at least one electrically-conducting line is furthermore operative for concurrently distributing a service other than the transport of data communication signals.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:
FIG. 1 shows a common prior art telephone line-wiring configuration for a residence or other building.
FIG. 2 shows a first prior art local area network based on telephone line wiring for a residence or other building.
FIG. 3 shows a second prior art local area network based on telephone line wiring for a residence or other building.
FIG. 4 shows a prior art non-wired communication network.
FIG. 5 shows modules according to the present invention.
FIG. 6 shows a local area network according to the present invention, wherein telephone wiring used for the wired segment and radio-frequency communication for the non-wired segment.
FIG. 7 shows a second embodiment of a local area network based on telephone lines as the wired segment and radio frequency communication for the non-wired segment.
FIG. 8 shows a kit for upgrading existing electrically-conducting lines to support a network according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The principles and operation of a network according to the present invention may be understood with reference to the drawings and the accompanying description. The drawings and descriptions are conceptual only. In actual practice, a single component can implement one or more functions; alternatively, each function can be implemented by a plurality of components and circuits. In the drawings and descriptions, identical reference numerals indicate those components that are common to different embodiments or configurations.
The invention is based on a wired/non-wired network adapter module (hereinafter referred to as “module”). A functional description of such a module 50 is shown in FIG. 5 . The module comprises a physical port 54 for connecting to the wired network. The communication with the wired network is carried by wired transceiver 51 . Wired transceiver port 54 and transceiver 51 are dependent upon the type of wired network. Interfacing a telephone line-based network requires a telephone line transceiver, while connecting to a power line network requires a power line dedicated modem. Additionally, the connection to the wired network may require specific means in order to meet regulatory and safety requirements, as well as specific means for ensuring that the basic service (e.g. telephony service, power distribution) is not substantially degraded or affected.
The non-wired segment interfaces via a port 55 . Port 55 communicates without an electrically conducting medium. Communication with this non-wired segment is handled by a non-wired modem/transceiver 53 . The term “non-wired modem” herein denotes any device capable of data communication without requiring an electrically conducting medium. The data to and from the wired segment and the data to and from the non-wired segment are handled by a protocol adapter 52 . Protocol adapter 52 may serve as a transparent unit, acting as a repeater/regenerator, dealing with the physical layer only of the OSI model. However, higher layers can also be handled by the protocol adapter 52 . In such a case, the protocol adapter will function as a bridge, router, gateway or any other adaptation mechanism as required.
Other facilities of module 50 may contain logic, control, processing, storage, power-supply and other components not shown in FIG. 5 . The communication supported by module 50 can be simplex (unidirectional, either from the wired towards the non-wired segment or vice-versa), half-duplex, or full duplex. A module 50 a connects a telephone line network segment to an RF network segment. Module 50 a employs a telephone line modem 51 a as the wired network interface, a radio-frequency modem 53 a as an interface to the non-wired network segment, and a protocol adapter 52 a . A module 50 b is an embodiment of the present invention, in which the telephone line transceiver can be implemented by a high-pass filter (HPF) 22 a and data terminal equipment (DCE) 23 a , as also used by Dichter as discussed previously.
FIG. 6 shows an embodiment of a network 60 according to the present invention that includes wired and non-wired segments. The wired segment is based on telephone wiring 5 within a building as described in FIG. 1 . While outlets 11 b and 11 c are unchanged, outlets 11 a and 11 d are replaced by outlets 61 d and 61 a , respectively, containing modules 50 d and 50 e respectively. Basic telephone service is retained by employing low-pass filters (LPF) 21 d and 21 a in outlets 61 d and 61 a respectively. The LPF's are coupled to telephone connectors 12 d and 12 a respectively, enabling connection of telephone devices. This is illustrated by a telephone 13 a connected by connector 14 a to connector 12 a in outlet 61 a . A Dichter-type data communication network is established by connecting data terminal equipment (DTE) via a modem and HPF, as illustrated by DTE 24 b connected to DCE 23 b , which is coupled to HPF 22 b , which is in turn directly coupled to telephone wiring 5 via connector 12 b in outlet 11 b.
The non-wired part of network 60 is based on radio frequency transmission, utilizing a pair of RF transceivers 53 ( FIG. 5 ). As shown in FIG. 6 , DTE's 24 d and 24 a are coupled to RF transceivers 53 c and 53 b , respectively. In turn, each such RF transceiver communicates with RF transceivers 53 d and 53 a , respectively, which are integrated within outlets 61 d and 61 a , respectively.
Integrating the wired and non-wired segments of the network is accomplished by modules 50 d and 50 e , each of which is illustrated by module 50 c in FIG. 5 . Modules 50 d and 50 e are integrated within outlets 61 d and 61 a , respectively. Each such module interfaces the wired segment of the network by a telephone modem. Each such modem contains a high-pass filter 22 and DCE 23 , as described previously for a Dichter-type network. Interfacing to the non-wired segment of network 60 is performed via an RF transceiver, wherein modules 50 d and 50 e comprises RF transceivers 53 d and 53 e respectively. Protocols and data conversion between both segments are performed by adapter 52 ( FIG. 5 ), wherein adapters 52 d and 52 e are integrated within modules 50 d and 50 e respectively.
Network 60 allows DTE's 24 d , 24 b and 24 a to communicate among themselves. While DTE 24 b is connected to the network via a wired connection, DTE's 24 d and 24 a can communicate in a non-wired manner. While FIG. 6 illustrates a single DTE connected by wires and two DTE's connected without wires, it is obvious that any number of DTEs of each type can be connected. Furthermore, while in network 60 each outlet supports a single wired or non-wired DTE connection, other implementations can also be supported. For example, an outlet can provide one or more wired connections simultaneously with one or more non-wired connections.
While FIG. 6 illustrates the case where module 50 is integrated in an outlet 61 , embodiments of the present invention also include those wherein the module is external to the outlet. Similarly, selective parts of a module may be integrated within an outlet while other parts are external. In all cases, of course, appropriate electrical and mechanical connection between the module and the outlet are required.
A network outlet is physically similar in size, shape, and overall appearance to a standard outlet, so that a network outlet can be substituted for a standard outlet in the building wall. No changes are required in the overall telephone line layout or configuration.
Network 60 provides clear advantages over hitherto proposed networks. For example, DTEs (e.g. PC's) located in different rooms can interconnect without the need to use any wires. A radio-frequency transceiver in each DTE communicates with the nearest outlet, and the outlets communicate between rooms over the telephone wiring media.
The invention can equally well be applied to the prior art wired network illustrated in FIG. 3 . FIG. 7 shows part of a network 70 . Outlet 31 a represents a prior-art network outlet. In order to interface to the non-wired network segments, an outlet 71 according to the present invention must be used. With the exception of RF transceiver 53 a within outlet 71 , which communicates with RF transceiver 53 b connected to a DTE 24 a , outlet 71 is similar to outlet 31 a . In this embodiment, the module includes two telephone line modems 23 b and 27 b , a three-port adapter 72 (for the two wired ports and the single non-wired port), and RF transceiver 53 a . The advantages offered by the prior-art topology apply also for this configuration.
While the present invention has been described above for the case where the wired media is based on a telephone line system and includes telephone wires and telephone outlets, the present invention can equally well be applied to other wired systems such as those based on power and cable television signal distribution. In the case of an electrical power distribution system, the electrical wires and outlets employed for power distribution in the house are used. Similarly, cable television wiring and outlets can also be used. In all cases, it may be necessary to retain the basic service for which the wiring systems were installed: telephony service, electrical power distribution, or television signals. This is usually achieved by adding the appropriate circuitry to separate the data communication network from the basic service, as well as to avoid interference of any kind between the two roles currently employing the same wiring. For example, the LPF's 21 a , 21 b , 21 c , and 21 d ; and HPF's 22 a , 22 b , 26 a , and 26 b ( FIG. 7 ) serve the role of separating the telephony service from the data communication network and vice-versa.
While the present invention has been described above for the case wherein the non-wired communication is accomplished by radio-frequency transmission, the present invention can be equally applied to other types of non-wired communication, such as:
1. Non-wired communication accomplished by other forms of electromagnetic transmission. Electromagnetic waves in various parts of the electromagnetic spectrum can be used for communication. For example, low-frequency electromagnetic radiation can be used to transmit audio-frequency signals over short distances without a carrier. Radio-frequency transmission is a special case of this general electromagnetic transmission. As noted previously, light is also a special case of electromagnetic radiation, but is herein treated separately because of the characteristics of light are distinctly different from those of electromagnetic transmission in other usable parts of the electromagnetic spectrum. 2. Non-wired communication accomplished by light. Either visible or non-visible light wavelength can be used for such transmission. As previously noted, currently, the most popular is infrared (IR) based communication. Most such systems require substantially ‘line-of-sight’ access. 3. Non-wired communication accomplished by sound. Either audible sound (20-20,000 Hz band), or inaudible sound (ultrasonic, above 20,000 Hz; or infrasonic, below 20 Hz).
In addition to the described data communication function, the network according to the present invention can also be used for control (e.g. home automation), sensing, audio, or video applications, and the communication can also utilize analog signals (herein denoted by the term “analog communication”). For example, a video signal can be transmitted in analog form via the network.
Upgrade Kit
The present invention also contemplates a kit for upgrading existing electrically conducting lines to support a network as described above. FIG. 8 illustrates an embodiment of such a kit containing an outlet 132 and an outlet 134 and installation instructions 136 . Outlet 132 has connection 144 for coupling to a wired segment and mounting points such as a flange 146 for installing in the building walls. Outlet 132 also has a jack 138 and a jack 140 for connecting to external devices via cables, and a transducer 142 for connecting to external data units via a non-wired segment. Within outlet 132 is a module according to the present invention, as previously described and illustrated in FIG. 5 . In one embodiment, transducer 142 is a radio frequency transceiver. In another embodiment, transducer 142 is a combined light-emitting diode and photocell receiver. In still another embodiment, transducer 142 is a combined speaker and microphone. Likewise, in one embodiment, jack 138 is a telephone jack. In another embodiment, jack 138 is an electrical power socket. In still another embodiment, jack 138 is a cable television jack. In one embodiment, jack 140 is a data jack. The embodiment of the kit illustrated in FIG. 8 has two outlets, outlet 132 and outlet 134 , which are illustrated as substantially identical. However, in another embodiment, the kit contains only outlet 132 . In still another embodiment, outlet 134 does not contain a transducer. Other variations are also possible in different embodiments.
It will also be appreciated that the outlet and the adapter module may be provided as separate components for use in upgrading existing wiring of a building to support a local area network having at least one wired segment and at least one non-wired segment. They may likewise find independent use for further expanding a hybrid network that has previously been upgraded according to the invention. Such an outlet is provided with a first coupler for coupling the outlet to the at least one non-wired segment, and a second coupler for coupling the outlet to the existing wiring via an adapter module. The adapter module may be either fully or partially integrated within the outlet.
A method for upgrading existing electrically conducting lines within a building to support a network according to the present invention involves:
(a) providing a wired modem; (b) providing a non-wired modem; (c) providing an adapter for handling the data communications between a wired segment and a non-wired segment; and (d) providing an outlet, and (e) equipping the outlet with the wired modem, the non-wired modem, and the adapter.
While the invention has been described with respect to a limited number of embodiments, it will be appreciated that many variations, modifications and other applications of the invention may be made. | A local area network ( 60 ) within a residence or other building, including both wired ( 5 ) and non-wired segments ( 53 ). The wired segments are based on new or existing wires ( 5 a, 5 b, 5 c, 5 d, 5 e ) in the building, wherein access to the wires is provided by means of outlets ( 61 a, 61 d ), such as a telephone system, electrical power distribution system, or cable television wiring system. The non-wired segments are based on communication using propagated waves such as radio, sound, or light (e.g. infrared). The wired and non-wired segments interface in the outlet, using a module ( 50 ) that serves as mediator between the segments. The module can be integrated into the outlet, partially housed in the outlet, or attached externally to the outlet. Such a network allows for integrated communication of data units ( 24 b ) connected by wires and data units ( 24 a, 24 d ) connected without wires. | 8 |
CLAIM OF PRIORITY
The present application claims priority from Japanese Patent Application No. 2004-022736 filed on Jan. 30, 2004, the content of which is hereby incorporated by reference into this application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a driving system for a semiconductor light emitting device. In particular, the present invention relates to improvements in performance of a laser exposing system to be used in a laser printer for printing images using distribution of static electric potentials formed by exposing laser beams emitted from a semiconductor laser as well as improvements in high quality images produced by the laser printer using the laser exposing system.
2. Description of the Related Art
Laser printers perform printing in the following manner: Pulsed laser beams are generated according to a pattern of an image to be printed; a charged photoconductive film is scanned with the laser beams for forming a static electricity image; the static electricity image controls toner adhesion thereto for forming the pattern to be printed: and the pattern is transferred on a surface of a printing stock. In the case of driving the semiconductor laser serving as a light source by the use of a pulsed current, a virtual junction temperature of the semiconductor laser rises with a time constant of a several microseconds to a several tens of microseconds after the application of current to the semiconductor laser. Generally, light output/current characteristics of the semiconductor laser are such that a threshold current 1 of laser oscillation is increased with the rise in virtual junction temperature. A conceptual diagram of the light output/current characteristics ( 2 , 3 ) in the case where the virtual junction temperature changes from T to (T+ΔT) is shown in FIG. 1 . A constant current source is usually used for driving the semiconductor laser because of its easy light intensity control; however, in the case of supplying a current of I 0 using the constant current source, the light output of the semiconductor laser is reduced from the initial output 4 to the output with the raised temperature 5 due to the change in light output/current characteristics. Accordingly, waveforms ( 6 , 7 ) of an electric current and an optical pulse when the constant pulsed current is applied are as shown in FIG. 2 , and the light intensity changes with time although the electric current value is kept constant.
Such phenomenon is the so-called droop phenomenon, which causes occurrence of irregularity of a printed image. Further, an associated phenomenon is a thermal crosstalk, which is problematic in a laser array having a plurality of light emitting devices on one and the same chip. The thermal crosstalk is caused by the reduction in light output due to the virtual junction temperature rise like the droop phenomenon; however, the phenomenon is different from the droop phenomenon in that the virtual junction temperature rises not because of the conduction of the device emitting light but because of a conduction of an adjacent device. That is to say even when a driving current 8 for the device emitting light does not change, a temperature of the device rises due to heating caused by a fluctuation in driving current of the adjacent device to reduce a light output 10 of the device emitting light, resulting in generation of irregularity of the printed image.
Electronics Letters; Vol. 28; P. 1460; 1991 describes the following: in the constant voltage driving wherein the driving source supplies pulses of a constant voltage to cause the semiconductor laser to emit light, the driving current is increased because a rising voltage of the current/voltage characteristics of the semiconductor laser is reduced when the virtual junction temperature rises. This compensates for the reduction in light output to mitigate the droop phenomenon. That is to say, owing to the difference between the voltage/current characteristics ( 11 , 12 ) due to the virtual junction temperature shown in FIG. 4 , the current flowing through the semiconductor laser at the time of application of the constant voltage is increased from the initial current value 13 to the current value after temperature rise 14 to compensate for the reduction in light output.
Owing to a series resistance of the semiconductor laser, the current increment is not sufficient, and the effect of stabilizing the light output achieved by the above method is so limitative that the light output moves to the point 15 of FIG. 1 . Therefore, it has been necessary to employ this method in combination with another droop reduction method such as biasing with a threshold electric current at the time of non-energization.
Japanese Patent Laid-open No. 5-129899 discloses a negative resistance circuit proposed for the realization of a bistable circuit. The object of the negative resistance circuit is different from that of the present invention which aims to achieve a stable driving of semiconductor lasers. In addition, the method of forming the negative resistance circuit is similar to that of a circuit described in embodiments of this invention.
Japanese Patent Laid-open No. 7-297448 discloses a negative resistance device arranged in series with a light emitting device so as to control on/off of the light emitting device. In spite of the structure of the serial provision of the negative resistance device and the light emitting device, the object thereof is bistability, and the structure does not have a function of compensating for a fluctuation in output light at a stable point, which is described in the present specification.
According to Japanese Patent Laid-open No. 05-13850, a bias current is changed depending on a change in threshold current caused by a temperature fluctuation in a driving circuit of an optical communication semiconductor laser, whereby the bias current whose value is substantially the same as that of the threshold current is continuously applied. Since a temperature change in gate voltage of an FET is used for controlling the bias current, it is possible to arrange the structure so as to equalize a change in bias current with a value corresponding to the temperature change in threshold current. The temperature change in this document corresponds to a change in ambient temperature common to both the FET and the semiconductor laser; however, the it does not cope with the fluctuation due to the virtual junction temperature change in laser output which is more local and rapid in response speed unlike the present invention which takes advantage of the temperature change in voltage of the semiconductor laser itself.
Electronics Letters: Vol. 28; P. 1460; 1991 describes the following; When a semiconductor laser for a laser printer is driven for light emission by a constant voltage circuit for generating a constant pulsed voltage, a current flowing through the semiconductor laser is increased with an increase in virtual junction temperature to compensate for a reduction in light output due to the virtual junction temperature rise, thereby reducing fluctuation in light output due to the temperature fluctuation.
The present invention provides a simple circuit structure capable of preventing a light output fluctuation which is otherwise caused by a temperature change due to energization of a semiconductor laser under the driving condition of small bias current.
SUMMARY OF THE INVENTION
In order to solve the above described problems in the conventional technologies, the present invention provides a function of maintaining a voltage to be applied to a predetermined portion of a driving circuit of a semiconductor laser at a constant value, wherein the predetermined portion of the circuit includes the semiconductor laser and a negative resistance circuit or a negative resistance device arranged in series with the semiconductor laser. In addition, a differential resistance of the predetermined portion of the circuit is set to a value that enables to equalize an increase in oscillation threshold current of the semiconductor laser caused by a temperature change with an increase in a driving current of the semiconductor laser caused by the temperature change. A proper value of the differential resistance is given by the following equation.
Δ I = ⅆ I 0 exp ( T - To Tc ) ⅆ T Δ T = I 0 exp ( T - To Tc ) Tc Δ T ( 1 )
Where Tc represents a characteristic temperature of the semiconductor laser; To represents a reference temperature (room temperature); and Io represents a threshold current at the reference temperature. A change in current value obtained by a change in rising voltage of current/voltage characteristics of the semiconductor laser due to a temperature change Δ is given by the following equation.
Δ
I
=
-
ⅆ
V
ⅆ
T
1
Rs
Δ
T
(
2
)
The equations (1) and (2) show that the following equation should be satisfied in order to compensate for a reduction in light output of the semiconductor laser due to the temperature rise by increasing the driving current in accordance with a change in current/voltage characteristics at the time of constant voltage operation.
-
ⅆ
V
ⅆ
T
1
Rs
=
I
0
exp
(
T
-
To
Tc
)
Tc
(
3
)
Taking an example from an AlGaInP semiconductor laser (wavelength: 630 nm) having a cavity of 300 μm and a stripe width of 5 μm, parameters required for calculating the optimum Rs from the equation (3) are values shown in a column of ALGaInP of Table 1, and the equation (3) is satisfied when a series resistance of the semiconductor laser is 2 Ω. However, a series resistance of an actual semiconductor laser is about 10 Ω, which is larger than the satisfactory value. It is possible that the series resistance cannot be reduced to 2 Ω since the value is substantially a lower limit of materials used for forming the semiconductor laser.
TABLE 1
AlGaInP
AlGaInAs
AlGaN
(λ630 nm)
(λ780 nm)
(λ405 nm)
dV/dT
6.0e −4
3.8e −4
3.8e −4
Tc
80 K
140 K
200 K
Io
24 mA
12 mA
50 mA
In this invention, in order to break through the limit of the conventional technologies, it is proposed to provide a circuit or a device having a negative differential resistance arranged in series with the semiconductor laser. As a result of subtracting a negative partial resistance from a series resistance of the semiconductor laser, a differential resistance of a predetermined portion of a driving circuit including the semiconductor laser becomes equal to a series resistance required for stabilizing the light output with respect to the fluctuation in virtual junction temperature by the constant voltage driving. Thus, it is possible to compensate for the thermal fluctuation of the semiconductor laser.
According to the invention, it is possible to perfectly compensate for the fluctuation in light output of the semiconductor laser caused by the fluctuation in virtual junction temperature. In addition, it is possible to reduce the number of components and production cost of an optical exposure system as a whole because it is unnecessary to monitor the light output of the semiconductor laser to dynamically feedback the light output to the driving circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a conceptual diagram showing light output/current characteristics of a semiconductor laser;
FIG. 2 is a conceptual diagram showing droop characteristics of the semiconductor laser;
FIG. 3 is a conceptual diagram showing thermal crosstalk of the semiconductor laser;
FIG. 4 is a conceptual diagram showing current/voltage characteristics of the semiconductor laser;
FIG. 5 is a block diagram showing a laser printer;
FIG. 6 is a diagram showing a laser driving unit of a first embodiment of the present invention;
FIG. 7 is a diagram showing a laser driving unit of a second embodiment of the invention;
FIG. 8 is a diagram showing a laser driving unit of a third embodiment of the invention;
FIG. 9 is a diagram showing a structure of a semiconductor laser of the third embodiment of the invention;
FIG. 10 is a diagram showing current/voltage characteristics of a tunnel diode of the semiconductor laser according to the third embodiment of the invention;
FIG. 11 is a diagram showing a laser driving unit of a fourth embodiment of the invention;
FIG. 12 is a diagram showing a structure of a semiconductor laser of the fourth embodiment of the invention;
FIG. 13 is a diagram showing current/voltage characteristics of a tunnel diode of the semiconductor laser according to the fourth embodiment of the invention;
FIG. 14 is a diagram showing a structure of a semiconductor laser of a fifth embodiment of the invention;
FIG. 15 is a diagram showing current/voltage characteristics of a tunnel diode of the semiconductor laser according to the fifth embodiment of the invention;
FIG. 16 is a diagram showing input output characteristics of a negative resistance circuit according to the invention; and
FIG. 17 is a diagram showing input output characteristics of a light emitting device and output characteristics obtained by applying 4.5 V (negative resistance circuit applied voltage) to the negative resistance circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiment 1
Hereinafter, a first embodiment of the present invention will be described with reference to the drawings. Shown in FIG. 5 is an exposure optical system of a laser printer to which the invention is applied. Laser beams 102 emitted from a semiconductor laser 101 are collimated by the use of a collimator lens 103 , and then the collimated beams are condensed on a rotating polygonal mirror 105 by the use of a condenser lens 104 . The laser beams 102 reflected by the polygonal mirror 105 are condensed by a non-spherical lens 106 so that the laser beams 102 may scan at a constant speed a drum 108 on which a photoconductive material 107 is applied. The semiconductor laser 101 is driven by a laser driving unit 109 . An output from the laser driving unit 109 is controlled by a signal from a signal processing unit 111 which converts externally input image information 110 into laser switching information.
A structure of the laser driving unit 109 is shown in FIG. 6 . This unit includes a constant current circuit, a Zener diode 113 , a negative resistance circuit 116 having two transistors ( 114 , 115 ), and a semiconductor laser 101 . The constant current circuit provides a constant current in response to the signal from the signal processing unit to a circuit using power supplied from 12 V power source. The Zener diode 113 maintains an input signal from a constant current source 112 at a predetermined voltage. The semiconductor laser is illustrated as two elements of an ideal diode 117 and a series resistance 118 in FIG. 6 .
The Zener diode 113 operates to maintain a voltage at an input terminal of the negative resistance circuit 116 at 4.5 V when the signal is on. A source terminal of the first transistor of the negative resistance circuit is connected to the 12 V power source via a control resistor 119 . When a potential difference between the terminals of the negative resistance circuit, a current supplied to the first transistor 114 is increased, and a gate voltage of the second transistor 115 is decreased due to a voltage drop of the control resistor 119 , whereby a current flowing through the second transistor is reduced. As a result, a negative resistance with which the passing current is reduced due to the increase in potential difference between the terminals is realized in the negative resistance circuit.
The semiconductor laser 101 used in this embodiment is a 630 nm AlGaInP strained quantum well laser having a cavity of 300 μm, a stripe width of 5 μm, a threshold current of 24 mA, a characteristic temperature of 80 K, and a series resistance of 10 Ω. A differential resistance Rn of the negative resistance circuit is represented by using resistance Rc of the control resistor and respective transmission admittances Y tr1 and Y tr2 of the first and the second transistor as follows:
Rn = - 1 Rc · Y tr1 · Y tr2 ( 4 )
In this embodiment, Rc, Y tr1 , and Y tr2 are set to 125 Ω, 0.01 S, and 0.1 S, respectively, so that the Rn becomes −8 Ω.
Current/voltage characteristics of the negative resistance circuit are shown in FIG. 16 . A current flowing through the circuit in which the semiconductor laser is connected to the negative resistance circuit in series is obtained from an intersection of curves as shown in FIG. 17 where the curve obtained by transforming the horizontal axis into 4.5-negative resistance circuit applied voltage is overlaid on the curve of current/voltage characteristics 13 of the semiconductor laser. This is because the applied voltage of the semiconductor laser should agree with a value obtained by subtracting the voltage drop caused by the negative resistance circuit from the voltage maintained by the Zener diode. Thus, the differential resistance of the circuit from the Zener diode terminal is 2 Ω, which is equal to a difference between differential resistances of the semiconductor laser and the negative resistance circuit, thereby satisfying the droop suppressing conditions.
Embodiment 2
Hereinafter, a second embodiment will be described with reference to the drawings. An exposure optical system of a laser printer to which the invention is applied is similar to that of the first embodiment except for using a simple circuit as shown in FIG. 7 as the laser driving unit. This unit includes a constant current circuit for providing a constant current to the circuit using power supplied from 12 V power source, a Zener diode 113 for maintaining an input signal from a constant current source 112 at a predetermined voltage, a field effect transistor 201 for controlling a current in accordance with a signal from a signal processing unit 111 , and a semiconductor laser 101 . The semiconductor laser is illustrated as two elements of an ideal diode 117 and a series resistor 118 in FIG. 7 .
The Zener diode 113 operates to maintain a voltage at an input terminal of the field effect transistor 201 at 4.5 V when the signal is on. The field effect transistor 201 is of normal open type. When the semiconductor laser is turned on, a signal processing unit applies a gate voltage of 4.5 V, whereas when the semiconductor laser is turned off, the signal processing unit applies a gate voltage of 12 V. A drain-gate voltage is increased with a reduction in drain voltage of the field effect transistor 201 , so that a current amount of the field effect transistor 201 is reduced. As a result, the field effect transistor 201 performs a negative resistance operation by which the current is reduced with an increase in applied voltage.
The semiconductor laser 101 used in this embodiment is a 630 nm AlGaInP strained quantum well laser having a cavity of 300 μm, a stripe width of 5 μm, a threshold current of 24 mA, a characteristic temperature of 80 K, and a series resistor of 10 Ω. A differential resistance Rn of the field effect transistor 201 is represented as below using transmission admittance Y tr of the field effect transistor 201 .
Rn = 1 Y tr ( 5 )
In this embodiment, Y tr is set to −0.125 S and Rn is set to −8 Ω to maintain a differential resistance of a load including the semiconductor laser at 2 Ω.
Embodiment 3
Hereinafter, a third embodiment of the invention will be described with reference to the drawings. An exposure optical system of a laser printer to which the invention is applied is similar to that of the first embodiment except for using a simple circuit shown in FIG. 8 as the laser driving unit, This unit includes a constant current pulsed source 300 , a Zener diode 113 , and a semiconductor laser 301 . The constant current pulsed source 300 provides a constant current that is responsive to a signal from a signal processing unit 111 to the circuit using power supplied from 12 V power source. The Zener diode 113 maintains an input signal from the constant current pulsed source 300 at a predetermined voltage. The semiconductor laser is illustrated as three elements of an ideal diode 117 , a series resistor 118 , and a tunnel diode 302 having a negative resistance in FIG. 8 . The Zener diode 113 operates to maintain a voltage at an input terminal of the semiconductor laser 301 at 4.5 V when the signal is on.
The semiconductor laser 301 of this embodiment is configured as shown in a cross-sectional view of FIG. 9 . More specifically, an n-type clad layer 304 (Se doped, p=7×10 17 cm −3 , 1.8 μm) made of (Al 0.7 Ga 0.3 ) 0.5 In 0.5 P, a multi quantum well active layer 305 , a p-type clad layer 306 (Zn doped, n=1×10 18 cm −3 , 1.8 μm) made of (Al 0.7 Ga 0.3 ) 0.5 In 0.5 P, a p-type GaAs layer 307 (Zn doped, n=1×10 20 cm −3 , 200 nm), an-n type GaAs layer 308 (Si doped, n=1×10 20 cm −3 , 200 nm), and a p-type GaAs layer 309 (Zn doped, n=3×10 19 cm −3 , 20 nm) are sequentially formed on an n-type GaAs substrate 303 . The multi quantum well active layer is composed of three Ga 0.5 In 0.5 P well layers 310 (thickness: 7 nm) and four (Al 0.5 Ga 0.5 ) 0.5 In 0.5 P barrier layer 311 (thickness: 4 nm) alternately sandwiching the Ga 0.5 In 0.5 P well layers 310 therebetween. Prom the p type GaAs layer 309 to the p type clad layer 306 made of (Al 0.7 Ga 0.3 ) 0.5 In 0.5 P are chemically removed so that the thickness thereof may be reduced to about 0.3 μm except for a stripe region 312 having a stripe width of 4 μm, and an n-GaAs current block layer 313 is formed thereon. Further, a p-GaAs layer 314 is formed on the N-GaAs current block layer 313 in order to reduce a contact resistance with a gold electrode 315 which is formed on the p-GaAs contact layer 314 . The p-type GaAs layer 307 , the n-type GaAs layer 308 , and the p-type GaAs layer 309 constitute a tunnel diode 302 of which current/voltage characteristics are as shown in FIG. 10 . Operation of the tunnel diode is as described below. A large tunnel current flows through a junction of the p-type GaAs layer 307 with the n-type GaAs layer 308 because both of the layers are doped with impurity at a concentration of as high as 1×10 20 cm −3 , and a voltage drop scarcely occurs at the junction. Since an impurity concentration of the p-type GaAs layer 309 is as relatively low as 3×10 19 cm −3 , a junction of the n-type GaAs layer 308 with the p-type GaAs layer 309 does not help to constitute a perfect tunnel diode. Instead, an Esaki diode is constituted, that is, a tunnel current flows through the junction in a low voltage region, but the tunnel current is reduced with an increase in voltage resulting in a temporary reduction, and a further increased voltage allows the an ordinary diode current to flow. As shown in FIG. 10 , a negative resistance region 316 having a differential resistance of about −8 Ω appears in the current/voltage characteristics of the tunnel diode. The negative resistance characteristics of the region makes it possible to set a differential resistance of the device as a whole to 2 Ω. It is thus possible to reduce a temperature fluctuation in light output by driving the device of this embodiment by way of the constant voltage driving.
Embodiment 4
Hereinafter, a fourth embodiment of the invention will be described in accordance with the drawings. An exposure optical system of a laser printer to which the invention is applied is similar to that of the first embodiment except for that the laser printer is a high speed laser printer using a semiconductor laser array having a plurality of light emitting devices integrated on a chip. This unit is composed of four independent driving circuits as shown in FIG. 11 in order to drive four array elements, respectively. Each of the circuits includes a constant current pulsed source 300 , a Zener diode 113 , and a semiconductor laser 401 . The constant current pulsed source 300 provides a constant current which is responsive to a signal from a signal processing unit 111 to the circuit using power supplied from 12 V power source. The Zener diode 113 maintains an input signal from the constant current pulsed source 300 at a predetermined voltage. The semiconductor laser array 401 is illustrated as three elements of an ideal diode 117 , a series resistance 118 , and a tunnel diode 302 having a negative resistance in FIG. 11 . The Zener diode 113 operates to maintain a voltage at an input terminal of the semiconductor laser 401 at 4.5 V when the signal is on.
The semiconductor laser 401 of this embodiment is an AlGaAs device having a wavelength of 780 nm as shown in FIG. 12 . This device comprises an n-type clad layer 402 (Se doped, p=7×10 17 cm −3 , 1.8 μm) made of (Al 0.5 Ga 0.5 )As, a multi quantum well active layer 403 , a p-type clad layer 404 (Zn doped, n=1×10 18 cm −3 , 1.8 μm) made of (Al 0.5 Ga 0.5 )As, a p-type GaAs layer 307 (Zn doped, n=1×10 20 cm −3 , 200 nm), an n-type GaAs layer 308 (Si doped, n=1×10 20 cm −3 , 200 nm), and a p-type GaAs layer 309 (Zn doped, n=3×10 19 cm −3 , 20 nm), which are formed on an n-type GaAs substrate 303 sequentially. The multi quantum well active layer is composed of three Al 0.1 Ga 0.9 As well layers 405 (thickness: 7 nm) and four Al 0.5 Ga 0.5 As barrier layers 406 (thickness: 4 nm) alternately sandwiching the Al 0.1 Ga 0.9 As well layers 405 therebetween. From the p-type GaAs layer 309 to the p-type clad layer 403 made of (Al 0.5 Ga 0.5 )As are chemically removed so that the thickness thereof is reduced to about 0.3 μm except a stripe region 312 having a stripe width of 4 μm. In order to protect a surface having the above-described structure, a silicon oxide film 407 is deposited on the surface, and a portion of the silicon oxide film 407 on a ridge is removed to provide an electrode 408 mainly comprising gold, thereby achieving the semiconductor laser structure. In this embodiment, such four stripe regions are provided at 10-micron intervals. The p-type GaAs layer 307 , the n-type GaAs layer 308 , and the p-type GaAs layer 309 constitute a tunnel diode 302 of which current/voltage characteristics are as shown in FIG. 13 . Operation of the tunnel diode is as described below. A large tunnel current flows through a junction of the p-type GaAs layer 307 with the n-type GaAs layer 308 because both of the layers are doped with impurity at a concentration of as high as 1×10 20 cm −3 , and a voltage drop scarcely occurs at the junction. Since an impurity concentration of the p-type GaAs layer 309 is as relatively low as 3×10 19 cm −3 , a junction of the n-type GaAs layer 308 with the p-type GaAs layer 309 does not help to constitute a perfect tunnel diode. Instead, an Esaki diode is constituted, that is, a tunnel current flows through the junction in a low voltage region, but the tunnel current is reduced with an increase in voltage resulting in a temporary reduction, and a further increased voltage allows the an ordinary diode current to flow. As shown in FIG. 13 , a negative resistance region 316 having a differential resistance of about −7 Ω appears in the current/voltage characteristics of the tunnel diode. The negative resistance characteristics of the region make it is possible to set a differential resistance of the device as a whole to 3 Ω. As is apparent from the characteristics of the 780 nm semiconductor laser shown in Table 1, it is possible to substantially compensate for a temperature fluctuation in light output of the semiconductor laser when the series resistance is 3 Ω.
Embodiment 5
Hereinafter, a fifth embodiment of the invention will be described in accordance with the drawings. An exposure optical system of a laser printer to which the invention is applied is similar to that of the first embodiment except for using a semiconductor laser array having a plurality of light emitting devices integrated on a chip. This unit is composed of four independent driving circuits as shown in FIG. 11 in order to driving four array elements respectively. Each of the circuits includes a constant current source 112 , a Zener diode 113 , and a semiconductor laser 501 . The constant current source 112 provides a constant current which is responsive to a signal from a signal processing unit 111 to the circuit using power supplied from 12 V power source. The Zener diode 113 maintains an input signal from the constant current source 112 at a predetermined voltage. The semiconductor laser is illustrated as three elements of an ideal diode 117 , a series resistor 118 , and a tunnel diode 302 having a negative resistance in FIG. 11 . The Zener diode 113 operates to maintain a voltage at an input terminal of the semiconductor laser 501 at 6 V when the signal is on.
The semiconductor laser 501 of this embodiment is an AlGaN device having a wavelength of 405 nm as shown in FIG. 14 . This device comprises an n-type clad layer 503 (Si doped, p=7×10 17 cm −3 , 1.8 μm) made of (Al 0.2 Ga 0.8 )N, a multi quantum well active layer 504 , a p-type clad layer 505 (Mg doped, n=1×10 18 cm −3 , 1.8 μm) made of (Al 0.2 Ga 0.8 )N, a p-type GaN 0.99 As 0.01 layer 506 (Mg doped, n=1×10 20 cm −3 , 200 nm), an n-type GaN 0.99 As 0.01 layer 507 (Si doped, n=1×10 20 cm −3 , 200 nm), and a p-type GaN 0.99 As 0.01 layer 508 (Mg doped, n=3×10 19 cm −3 , 20 nm), which are formed on an n-type GaN substrate 502 sequentially. The multi quantum well active layer is composed of three In 0.1 Ga 0.9 N well layers 509 (thickness: 7 nm) and four Al 0.2 Ga 0.8 N barrier layers 510 (thickness: 4 nm) alternately sandwiching the Al 0.1 Ga 0.9 As well layers 509 therebetween. The layers from the p-type GaN 0.99 As 0.01 layer 508 to the p-type clad layer 505 made of (Al 0.2 Ga 0.8 )N are removed by reactive ion etching so that the thickness thereof is reduced to about 0.3 μm except a stripe region 312 having a stripe width of 2.5 μm. In this embodiment, the stripe regions are provided at 10-micron intervals. The p-type GaN 0.99 As 0.01 layer 506 , the n-type GaN 0.99 As 0.01 layer 507 , and the p-type GaN 0.99 As 0.01 layer 508 constitute a tunnel diode 302 of which current/voltage characteristics are as shown in FIG. 15 . Operation of the tunnel diode is as described below. A large tunnel current flows through a junction of the p-type GaN 0.99 As 0.01 layer 506 with the n-type GaN 0.99 As 0.01 layer 507 because both of the layers are doped with impurity at a concentration of as high as 1×10 20 cm −3 , and a voltage drop scarcely occurs at the junction. Since an impurity concentration of the p type GaN 0.99 As 0.01 layer 508 is as relatively low as 3×10 19 cm −3 , a junction of the n type GaN 0.99 As 0.01 layer 507 with the p type GaN 0.99 As 0.01 layer 508 does not help to constitute a complete tunnel diode. Instead, an Esaki diode is constituted, that is, a tunnel current flows through the junction in a low voltage region, but the tunnel current is reduced with an increase in voltage resulting in a temporary reduction, and a further increased voltage allows the an ordinary diode current to flow. As shown in FIG. 15 , a negative resistance region 316 having a differential resistance of about −9 Ω appears in the current/voltage characteristics of the tunnel diode. The negative resistance characteristics of the region make it possible to set a differential resistance of the device as a whole to 1 Ω. As is apparent from the characteristics of the 405 nm semiconductor laser shown in Table 1, it is possible to substantially compensate for a temperature fluctuation in light output of the semiconductor laser when the series resistance is 1 Ω.
With the present invention, it is possible to largely suppress the droop characteristics, which frequently present problems with application of a semiconductor laser to a printer, with the use of a relatively simple circuit structure; therefore, the invention has remarkably great industrial applicability.
Denotations of reference numerals used in the drawings are as follows:
1 : threshold current, 2 : light output/current characteristics (temperature T), 3 : light output/current characteristics (temperature T+ΔT), 4 : initial output, 5 : output with raised temperature, 6 : waveform of pulsed current, 7 : waveform of light pulse, 8 : driving current of device emitting light, 9 : driving current of adjacent device, 10 : light output of device emitting light, 11 : current/voltage characteristics (temperature T), 12 : current/voltage characteristics (temperature T+ΔT), 13 : initial driving current, 14 : driving current after temperature rise, 15 : light output at constant voltage driving, 101 : semiconductor laser, 102 ; laser beams, 103 : collimator lens, 104 : condenser lens, 105 : rotating polygonal mirror, 106 : non-spherical lens system, 107 : photoconductor, 108 : drum, 109 : laser driving unit, 110 : image information, 111 : signal processing unit, 112 : constant current source, 113 : Zener diode, 114 : first transistor, 115 : second transistor, 116 : negative resistance circuit, 117 : ideal diode, 118 : series resistance, 201 : field effect transistor, 301 : semiconductor laser, 302 : tunnel diode, 303 : n-type GaAs substrate, 304 : n-type clad layer made of (Al 0.7 Ga 0.3 ) 0.5 In 0.5 P, 305 : multi quantum well active layer, 306 : p type clad layer made from (Al 0.7 Ga 0.3 ) 0.5 In 0.5 P, 307 : p type GaAs layer, 308 : n type GaAs layer, 309 : p type GaAs layer, 310 : Ga 0.5 In 0.5 P well layer, 311 : (Al 0.5 Ga 0.5 ) 0.5 In 0.5 P barrier layer, 312 ; stripe region, 313 : n-GaAs current blocking layer, 314 : p-GaAs contact layer, 315 : gold electrode, 316 : negative resistance region, 400 : constant current source, 401 : semiconductor laser, 402 : n-type clad layer made of (Al 0.5 Ga 0.5 )As, 403 : multi quantum well active layer, 404 : p type clad layer made of (Al 0.5 Ga 0.5 )As, 405 : Al 0.5 Ga 0.9 As well layer, 406 ; Al 0.5 Ga 0.5 As barrier layer, 407 : silicon oxide layer, 408 : gold electrode, 409 : semiconductor laser array, 501 : semiconductor laser, 502 : n-type GaN substrate, 503 : clad layer made of (Al 0.2 Ga 0.9 )N, 504 : multi quantum well active layer, 505 : p-type clad layer, 506 : p-type GaN layer, 507 : n-type GaN layer, 508 ; p-type GaN layer, 509 : well layer made of Al 0.1 Ga 0.9 N, 510 : barrier layer made of Al 0.5 Ga 0.5 N, 511 : p-type GaN layer, 512 : p-type clad layer made of (Al 0.2 Ga 0.8 )N. | When a semiconductor laser is energized, a virtual junction temperature rises to reduce a threshold current, which fluctuates a light output by the unit of a several microseconds, thereby causing printing irregularity. An object of the invention is to prevent the fluctuation in light output occurring due to the temperature change caused by the energization of the semiconductor laser with a simple circuit structure and under the driving condition of a small bias current. A constant voltage driving is performed with a circuit or device having negative resistance characteristics being arranged in series with the semiconductor laser. Thus, the reduction in light output of the semiconductor laser due to the temperature rise is compensated for by an increase in driving current thanks to a reduction in rising voltage of current/voltage characteristics. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to an oil-in-water emulsion to remediate the loss of the drilling mud circulation while drilling a well. The emulsion may be used to prevent drilling fluids from entering a subterranean formation.
BACKGROUND OF THE INVENTION
[0002] Drilling fluids are used to drill holes in the Earth's crust. The drilling fluids are typically circulated through the drill pipe, through the drill bit, then up to the surface through the annular space between the drill pipe and the formation. It is important for the drilling fluids to circulate down the hole and back up to the surface. The drilling fluids are used to:
a) seal permeable formation b) maximize penetration rates c) minimize reservoir damage d) cool and lubricate the drilling bit e) clean the drill bit nozzles f) control formation pressures g) maintain well bore stability h) prevent the well from caving i) power the drill bit j) and, in some cases, provide a medium through which data can be transmitted to the surface
[0013] The loss of drilling fluid circulation increases the risk of:
a) possible blow out because of a drop in the mud level, or a failure to control formation pressure b) possible sticking the drill pipe or drill bit because of poor cutting removal c) excessive cost because of loss of mud, increasing rig time and remedial cementing operations d) losses to the producing zone resulting in extensive formation damage which can negatively affect future oil or gas production e) gas migration f) and well bore instability
[0020] In extreme cases of lost circulation, almost all of the drilling fluids are lost to the formation. In those cases, the risk of blow out is significant. In addition, there is also a significant risk of getting the drill bit trapped in the hole. Extreme cases of lost circulation can be dangerous and cause significant down time which affects the economics of drilling a well. In some cases, it can cause $1,000,000 or more of additional cost to a well.
[0021] Traditionally, lost circulation materials are added to the drilling fluids to eliminate or reduce the loss of drilling fluids to the formation while drilling. Some examples are bentonite, polymer, solid polymer fibers (polyethylene, polypropylene, etc), sawdust, flaked cellophane, crushed or ground calcium carbonate, shredded newspaper, cotton seed hulls, and crushed walnut shells. However, such agents have not been proven satisfactory for extreme cases of lost circulation. In those cases, the traditional solution has been to increase the drill fluid injection volume by an order of magnitude or more, or by cementing the formation.
[0022] The use of an oil-in-water emulsion to seal a subterranean formation was first described by Weigand in 1957 (U.S. Pat. No. 2,805,720). In this case, an asphalt-in-water emulsion is forced through the formation that requires sealing. By forcing the emulsion through the formation, the emulsion breaks, the asphalt is freed and the asphalt forms a seal.
[0023] Another example came in 1964 by Brandt et al in (U.S. Pat. No. 3,159,976) where the use of a cationic asphalt emulsion to plug a subterranean formation was described. A cationic surfactant was used to manufacture asphalt-in-water emulsion. The emulsion was broken underground by following it with a caustic solution. While this can prove effective in some cases, in reality, it is very difficult to ensure that the breaker fluid follows the same path as the emulsion; therefore it is very difficult to ensure that all the emulsion is broken.
[0024] The use of an oil-in-water emulsion to seal gas formations has also been described previously in “Application of Emulsion Flow for Sealing Leaky Gas Wells” by Zeidani et al. (Conference paper, Canadian International Petroleum Conference, Jun. 13-15, 2006 2006, Calgary, Alberta). The authors relied on the capture of the small droplets by the formation to seal it. This method is not expected to work in formations with large porosity that are causing extreme cases of lost circulation; the emulsion droplets are much too small relative to the cavity size.
[0025] It is an object of the present invention to provide an improved lost circulation agent to seal subterranean formations. The present invention aims to better satisfy this need.
SUMMARY OF THE INVENTION
[0026] Unlike other emulsion sealing methods where the emulsion is prepared such that the emulsion is either filtered by the formation or breaks once in contact with a second breaker fluid, the current invention relies on the emulsion to break once in contact with the formation fluids, triggered by a chemical reaction of the surfactant with the formation fluids. The careful selection and addition of a surfactant that is soluble in the water used to manufacture the emulsion and insoluble in the presence of the formation water permits the emulsion described according to the present invention to seal the subterranean formation.
[0027] Based on the previous work in this field, an oil-in-water emulsion capable of self-breaking in the presence of the formation or formation fluids would be very beneficial for sealing subterranean formations.
[0028] According to one aspect of the present invention there is provided an oil in water emulsion for use in sealing a subterranean formation, said oil-in-water emulsion comprising an aqueous continuous phase and a hydrocarbon internal phase, said emulsion stabilized by a surfactant, wherein said surfactant has the following properties: (i) has an HLD (“Hydrophilic Lipophilic Deviation” of a surfactant, see equations below at paragraphs 030-032) that is less than 0; (ii) is soluble in the water used to manufacture the emulsion, and (iii) is insoluble in the subterranean water.
[0029] In yet a further aspect of the present invention, there is provided a method for preparing an oil-in-water emulsion comprising: combining water and a surfactant to form an aqueous solution; combining said aqueous solution with a hydrocarbon and mixing until said oil-in water emulsion is formed, wherein said surfactant comprises the following properties: (i) has an HLD that is less than 0; (ii) is soluble in the water used to manufacture the emulsion, and (iii) is insoluble in the subterranean water.
[0030] Another advantage of the present invention is the ability to recover the hydrocarbon component of the emulsion if applied in the producing formation.
[0031] These and other features, aspects and advantages of the present invention will become better understood with regard to the following description.
DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is a graph of pressure at the inlet of the core and mass of fluids produced as a function of time, over the injection of the emulsion for example 1.
[0033] FIG. 2 is a graph of pressure at the inlet of the core and mass of fluids produced as a function of time, during the injection of water that follows the emulsion injection for example 1.
[0034] FIG. 3 shows photographs of the core after the experiment for example 1.
[0035] FIG. 4 is a graph of pressure at the inlet of the core and mass of fluids produced as a function of time in example 2.
[0036] FIG. 5 is a graph of pressure at the inlet of the core and mass of fluids produced as a function of time during the injection of water that follows the emulsion injection for example 2.
[0037] FIG. 6 shows photographs of the core after the experiment for example 2.
[0038] FIG. 7 is a graph showing effective permeability during the water injection that follows the emulsion injection.
DETAILED DESCRIPTION OF THE INVENTION
[0039] The current invention relates to a novel method for sealing a subterranean formation using an oil in water emulsion. The present invention also relates to a process for preparing an oil-in-water emulsion, and to the emulsions obtained thereby.
[0040] The term “oil”, as used herein, including the claims, comprises oil or hydrocarbon of any type or composition.
[0041] The oil-in-water emulsion of the present invention comprises a hydrocarbon, an aqueous medium and the use of a surfactant to emulsify and stabilise the emulsion. The emulsion is an oil-in-water emulsion where the oil is distributed as small oil droplets within a water or aqueous continuous phase.
[0042] The emulsions and methods of making such emulsions according to the present invention can be used to seal a formation in order to prevent other fluids to enter.
[0043] The hydrocarbon phase used for making the emulsion should preferably comprise hydrocarbons previously produced from the same formation where the emulsion will be injected. In addition, the hydrocarbon should be naturally occurring bitumen or asphalt. Ideally, the hydrocarbon will be tacky under formation temperature, such that the breaking of the emulsion forms a solid mass capable of at least partially sealing the wellbore's walls. In using produced oil from the reservoir, such as naturally occurring bitumen, compatibility between the injected fluid comprising the emulsion and the reservoir is maintained.
[0044] An advantage of the present invention is the ability to later recover the hydrocarbon used to seal the formation. While being economically beneficial, it also considerably reduces the chance of formation damage when using this type of sealant. For example, if the sealant is applied to a bitumen formation, it can be recovered by subsequent steaming of the formation, a standard process to produce bitumen from a bitumen-laden formation.
[0045] While it may be preferable to use the same hydrocarbon as what is present in the reservoir to manufacture the emulsion, if desired, any other type of hydrocarbon could also be used.
[0046] It is an advantage of the present invention to have the breaking of the emulsion triggered by contact of the emulsion with formation fluids. This ensures that the emulsion breaks only where needed.
[0047] Another advantage of the present invention is that standard lost circulation materials can be added to the emulsion so to give structural strength to the hydrocarbon seal left by the broken emulsion in order to better seal larger cavities.
[0048] A further advantage of the present invention is the ability to use the emulsion as a drilling fluid. The emulsion's rheology can be modified using water soluble polymers such that its rheology is suitable for drilling.
[0049] An additional advantage is the ability to use the emulsion as a pill or slug. In this application, a water compatible with the emulsion can be injected first, followed by the emulsion, followed by a small emulsion compatible spacer, and then followed by a water not compatible with the emulsion. This ensures that the emulsion breaks in the formation, that the emulsion is pushed into the formation and that the emulsion does not stay within the wellbore. This procedure can also be applied using a packer to isolate the formation and prevent fluid returns from the procedure to the surface.
[0050] The methods and compositions of this invention incorporate a surfactant to stabilise the oil-in-water emulsion. The surfactant is added to the hydrocarbon and water solution during the preparation of the emulsion. According to the invention, the chemical nature of the surfactant compound may be anionic, cationic or non-ionic. Preferably, the surfactant that is used is an anionic surfactant.
[0051] In order to ensure emulsion stability, the surfactant is selected according to the oil and brine chemistries of the reservoir. The surfactant should have the following properties: (a) has an HLD value that is effective in producing an oil-in water emulsion; (b) is soluble in the water used to manufacture the emulsion, and (c) is insoluble in the subterranean formation water.
[0052] The selection of a suitable surfactant is also based on the oil and water chemistries of the hydrocarbon and aqueous phase, for example, by using well-known theories such as the HLD Theory of Jean-Louis Salager. The HLD number (or Hydrophilic Lipophilic Deviation) of a surfactant is a well known quantity and needs no extended explanation herein. The reader is referred to J. L. Salager et al., “Principles of Emulsion Formulation Engineering,” in Dinesh O. Shah and K. L Mittal, eds., Adsorption and Aggregation of Surfactants in Solution (CRC Press, 2002) 501-523. Using the HLD equations, the effects of the salts present in the aqueous phase (e.g. Na+, Ca2+, Mg2+, etc) can be predicted. For example, the salt content of the water in the aqueous phase is known to affect the cloud point of non-ionic surfactants and sometimes will trigger precipitation of anionic surfactants. In the foregoing and hereinafter, HLD means Salager's equation and for the reader's reference, the equations for non-ionic and ionic surfactants are reproduced below. The HLD equations for all other types of surfactants have not been reproduced below but are accessible by referring to Salager's HLD Theory as described above.
[0053] The HLD of a surfactant, for a non-ionic surfactant is:
[0000] HLD=α−EON− k ACN− bS+aC A +c ( T−T ref )
[0000] wherein EON is the average number of ethylene oxide groups per non-ionic surfactant molecule, ACN is the alkane carbon number, S is the salinity as wt % NaCl, C A is the alcohol concentration, T is the Temperature and α is a parameter that is characteristic of the surfactant lipophilic group type and branching. It increases linearly with the number of carbon atoms in the alkyl tail. The k, a, b, and c are numerical coefficients.
[0054] The HLD equation of a surfactant, for an ionic surfactant is:
[0000] HLD=σ+ ln ( S )− k ACN+ c ( T−T ref )+ aA
[0000] wherein σ is a parameter that is characteristic of the surfactant, S is the salinity as wt % NaCl, ACN is the alkane carbon number, T is the temperature, and A is the percentage of alcohol added. k, c and a are numerical coefficients.
[0055] When the HLD>0, a Winsor type II phase behaviour is exhibited and it is the oil in the phase that contains most of the surfactant. At HLD=0 formulation, the affinity of the surfactant is the same for both phases and a very low minimum of interfacial tension is exhibited. When the HLD<0 the affinity of the surfactant for the aqueous phase dominates, and a so-called Winsor type I phase behaviour is exhibited in which a surfactant-rich aqueous phase is in equilibrium with an essentially pure oil phase.
[0056] As such, it is preferred to select a surfactant with an HLD of less than zero, when present in the water used to manufacture the emulsion.
[0057] In addition, it is also preferred that the surfactant is insoluble in the subterranean formation water. In other words, the surfactant must either precipitate in the subterranean formation water, or must have a HLD of zero or greater than zero in the subterranean formation water.
[0058] In a preferred embodiment, an anionic surfactant that precipitates in the presence of calcium ions is used. Examples of anionic surfactants that could be considered for the oil-in-water emulsion of the present invention include and are not limited to:
Linear alkyl benzene sulfonate Branched alkyl benzene sulfonate Linear alkyl sulfonate Branched alkyl sulfonate Linear sulfate Branched sulfate
[0065] Surfactants in the sulfonate family are especially interesting since they are usually soluble in fresh water while being insoluble in the presence of calcium ions. Subterranean formations will often show high levels of calcium ion, while drilling fluids are often manufactured with fresh water. The calcium gradient between the drilling fluid and the subterranean formation is in those situations an ideal trigger mechanism for breaking the emulsion.
[0066] In a second embodiment of this invention, a non-ionic surfactant with a cloud point temperature equal or lower than the formation temperature is selected. It is imperative to assure that the temperature of the drilling fluid stays below the formation temperature, and below the cloud point of the surfactant. Examples of non-ionic surfactants that could be considered for the oil-in-water emulsion of the present invention include and are not limited to:
Nonyl phenol polyethoxyalte Linear alcohol polyethoxylates Branched alcohol polyethoxylates Caster oil polyethoxylates Synthetic alcohol polyethoxylates
[0072] In a third embodiment of this invention, a non-ionic surfactant is selected, such that the surfactant has a cloud point above formation temperature when present in the emulsion water and a cloud point below formation temperature when present in the subterranean formation water. In this embodiment, it is necessary for the subterranean formation water to be more saline than the emulsion water. The difference in salt concentration affects the cloud point of the selected non-ionic surfactant. The higher the salt concentration, the lower the cloud point temperature of the selected non-ionic surfactant will be. Examples of non-ionic surfactants that could be considered for the oil-in-water emulsion of the present invention include and are not limited to:
Nonyl phenol polyethoxyalte Linear alcohol polyethoxylates Branched alcohol polyethoxylates Caster oil polyethoxylates Synthetic alcohol polyethoxylates
[0078] In a fourth embodiment of this invention, an anionic surfactant is selected such that the surfactant has a neutral charge at neutral pH and a negative charge at a pH higher than 7. Examples of anionic surfactants that could be considered for the oil-in-water emulsion of the present invention include and are not limited to:
Naturally occurring organic acids that are already present in the crude Naphthalene sulfonic acids Naphthalene carboxylic acids
[0082] In a fifth embodiment of this invention, a cationic surfactant is selected such that the surfactant has a neutral charge at neutral pH and a positive charge at a pH less than 7. Examples of cationic surfactants that could be considered for the oil-in-water emulsion of the present invention include and are not limited to:
Tallowalkyl amines Cocoalkyl amines Dicocoalkyl amines Oleyl-dimethyl amines
[0087] It should be noted that sometimes, the alkyl chain in some of the surfactants mentioned above can improve the surfactant's ability to stay dissolved in concentrated brine solutions. In addition, linear alkyl chains are preferable to branched alkyl chains since they are more readily biodegradable. The selection of other typical surfactants would be known to one familiar with the art.
[0088] A polymer may optionally be added to the aqueous medium prior to emulsification. A polymer may be used to increase the viscosity of the emulsion and therefore, also increase the stability of the emulsion to sedimentation or creaming. A suitable polymer may be selected from the standard polymer family used in drilling muds such as xanthan gum or chemically modified cellulose gum.
[0089] The emulsions of this invention are prepared by mixing an aqueous phase with the oil phase in any manner. The oil-in-water emulsion is typically manufactured using standard emulsification equipment, such as colloidal mills or static mixers. In a particularly preferred embodiment, the emulsions of the invention are prepared using colloidal mills because of their ease of use and their adaptability to different process conditions. However, different emulsification equipment and shearing devices could also be used, as would be known to one of ordinary skill in the art.
[0090] The oil in water emulsion is formed by adding the hydrocarbon to the aqueous medium, in small aliquots or continuously and placing the mixture in a colloidal mill for a time sufficient to disperse the oil as small droplets in the continuous aqueous phase. The hydrocarbon content may vary from 0.1% to 90%, however it is preferred to have an emulsion comprising about 50% to about 70% volume percent hydrocarbon.
[0091] If the step of adding a polymer is used, the polymer can be added to the water prior to emulsification or added directly to the oil-in water emulsion.
[0092] An optional component consisting of standard lost circulation material can also be added for extreme cases of large porosity formation needing to be sealed. The lost circulation material is typically one or a combination of bentonite, polymer, solid polymer fibers (polyethylene, polypropylene, etc), sawdust, flaked cellophane, crushed or ground calcium carbonate, shredded newspaper, cotton seed hulls, and crushed walnut shells
[0093] The following laboratory test was conducted to demonstrate the effectiveness of the emulsion as a sealing agent for a subterranean formation.
EXAMPLE 1
[0094] The emulsion sealing agent was tested in a core flood apparatus containing an unconsolidated core made from Ottawa sand of 100 to 140 mesh and with dimensions of 2″ diameter by 9″ long. A computer recorded the pressure and the cumulative weight of fluids produced versus time. The porosity was measured using gas expansion. In the gas expansion method, a known volume of nitrogen gas at a known pressure is equilibrated with the core. Once equilibrated, the pressure is measured again. Using the initial volume and pressure, the final pressure, and known fitting volumes, the pore volume of the core can be calculated. The Van der Waals correction to the ideal gas law is used to calculate the pore volume. The core initial permeability to water is measured by flowing water through the core at a known pressure and measuring the water flow rate exiting the core. The porosity was 31%, while the permeability was 5 Darcy. After the porosity and permeability measurements, the core is filled with a brine solution representing the formation being studied. In this case, the brine solution contained 30,500 ppm of sodium ions, 3,347 ppm of calcium ions, with chloride as the counter ion.
[0095] An emulsion was formulated, consisting of 70% naturally occurring bitumen, 29.8% tap water and 0.2% alkyl benzene sulfonate, sodium salt. The emulsion was manufactured using a colloidal mill model SEP 0.3B from DenimoTech A/S.
[0096] The emulsion was pumped through the core at a constant pressure of 600 psi at the pump for 0.67 pore volumes. FIG. 1 shows the pressure and mass against time of the emulsion flood. The drop of pressure at the end of the graph is when the pump shut off. After the injection of emulsion, 4.1 pore volumes of tap water are pushed through at 600 psi. FIG. 2 shows the pressure and mass response over time for the water push. Initially the pressure held above 600 psi for 18 minutes and then steadily decreased to 70 psi after an hour. The pressure then slowly decreased to 45 psi after 2.5 hours. The mass did not increase until the pressure decreased at 18 minutes. It then steadily climbed until the 4.1 pore volume was reached. FIG. 3 show the core after the run. A clear split between oil and untouched sand was noted. The water did not carry any of the oil further down the core.
EXAMPLE 2
[0097] Another example was performed with the same core flood apparatus containing an unconsolidated core made from round and washed ¾″ pebbles and with dimensions of 2″ diameter by 12″ long. The same emulsion as Example 1 was used, expect that 15% by mass of a lost circulation material (LCM) mixture of saw dust and crush nut shells was added to seal the larger cavities. Half of a pore volume of LCM containing emulsion was pumped into the brine filled core at 1 ml/min. It was followed by 1.5 pore volumes of tap water at 600 psi. FIG. 4 shows the emulsion flood response. The pressure spikes show the core plugging. The mass increase is stair-like, suggesting the increase and more effective blockage of pore space. FIG. 5 shows the response to the water flood. Initially the emulsion and LCM held back 35 psi of pressure before allowing water flow. The pressure decreased to around 8 psi. FIG. 6 show an increase in LCM oil pack at the inlet of the core. The pebbles do not fall out of place, but require digging out with metal spoon. FIG. 7 shows the effective permeability of the core throughout the run. A final effective permeability of 0.15 D represents a 4,000,000 times decrease in permeability compared to the initial estimated permeability of 200,000 D.
[0098] Although embodiments of the invention have been described above, it is not limited thereto and it will be apparent to those skilled in the art that numerous modifications form part of the present invention insofar as they do not depart from the spirit, nature and scope of the claimed and described invention | An oil-in-water emulsion is provided to place a sealant within a subterranean formation by being deployed into the formation to reacte with the formation's included water to break the emulsion, leaving the emulsified components, some of which act as the sealant to form at least a partial seal. The emulsion does not form a seal until emulsified in response to formation water conditions (salinity, pH, calcium ion concentration, temperature), and can be a drilling fluid or a pill during drilling activities. | 1 |
BACKGROUND OF THE INVENTION
The present invention generally involves connectors for piping and more particularly discloses what is generally termed a "quick connector" or union. This invention, in one particular embodiment, is useful in the drilling, production, and workover of oil and gas wells.
In large industrial operations and more particularly in the oil and gas industry it is often desirable and many times imperative that extremely high pressure fluids be pumped continuously from large powerful pumping systems into hydraulicly driven machinery or, as in the case of oil well servicing, directly into the borehole penetrating the underground formation. The fluids pumped encompass a broad range of liquids, some caustic and corrosive, some abrasive, and some very viscuous.
Oftentimes it is imperative to be able to place a movable pumping system, such as a truck or skid mounted hydraulic intensifier, at an oil well site and quickly supply high pressure fluid to the wellbore to acidize, fracture, or kill and prevent a blowout of the oilwell. The pumping system is usually connected to the wellbore by piping commonly called steel hose, and the connections between the sections of hose, the truck, and the wellhead must be capable of quick connections, good sealing ability, and high pressure capability under abrasive and corrosive conditions.
Conventional connectors for steel hose generally comprise a male connector end and a female connector end. The male end or the female end normally carries a primary seal consisting of a resilient seal such as an elastomeric radial seal or an O-ring seal. A secondary metal-to-metal seal may be attempted to back up the primary seal. One example of such a connector is disclosed in the '78-79 World Oil Catalog at page 2513 and is designated the Weco R Misaligning Union.
This conventional union has as its primary seal an elastomeric O-ring located in the male portion of the connector. Both the male and female connectors have arcuate seating shoulders to allow misalignment of the two pieces of up to 15°.
One of the major defects of the conventional connector assemblies is the use of an elastomeric seal as the primary seal. This exposes the seal to the high-pressure corrosive and abrasive environment passing through the piping. It also tends to extrude the seal into the flowstream which eventually results in the seal member blowing inward into the flowstream and lodging in a sensitive flow meter or other analytical instrument downstream from the connector. This is a particularly bad problem when the connectors are used in the production piping leading away from a high pressure oil or gas well.
Another serious defect of the conventional connectors is their tendency to vibrate loose or "back off" when in service. Because of the nature of these connectors and their use of an elastomeric primary seal, only a small amount of unthreading of the connector union allows loosening of the male and female ends to where the seal is quickly and easily pulled into the flowstream causing not only a loss of pressure at the connection, but also the accompanying damage to downstream instruments and tools. Because the conventional unions make-up and seal only at the very end of their confinement, a loosening of as little as one-fourth turn on the union by backing off of the thread can cause seal loss.
Backing off of the threaded portion of a connector can be a common occurrence due to several factors. One factor is the constant physical vibration from the pump motors to which the connection is attached. A second factor contributing to back-off is the constant high-pressure pump surges which cause the hydraulics to act internally and externally to loosen the connectors.
The present invention overcomes these deficiencies of the prior art by providing a quick connector which utilizes an interference-fit primary metal-to-metal seal backed up by a secondary elastomeric seal and having a locking means to prevent backing off of the threaded portions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 consists of a cross sectional side view of one preferred embodiment of the invention;
FIG. 2 illustrates a second embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Refering to the drawing, in which a cross sectional side view of the preferred embodiment of the invention is illustrated, a connector assembly 10 is shown having a male connector 11 and a female connector 12 both of which are generally cylindrical in configuration and have conically tapered surfaces formed thereon and therein, respectively. A union or collar 13 is rotatably held on the outside of the male connector 11 and has an internally threaded cylindrical end section 14 arranged for threaded engagement with a complementary externally threaded section 15 on female portion 12. The threads of sections 14 and 15 may be of the conventional cylindrical Acme or buttress threads or of any other known thread design such as tapered or stepped threads.
Male connector 11 has an external annular shoulder 16 formed thereon and projecting outwardly therefrom arranged for abutment with a matching inner annular shoulder 17 formed in union 13. This abutment shoulder arrangement 16 and 17 provides the means for drawing male connector 11 into sealing engagement with female connector 12 by threading section 14 onto section 15 of the female connector 12. A retainer ring 18 is snapped into an annular groove 19 formed in male connector 11 to retain the end of union 13 between ring 18 and shoulder 16 which also protects the conical tapered sealing surface on the male connector 13 when the quick connector is disassembled. One or more lugs 20 are attached to or integrally formed on union 13 to allow impact tightening of the union on connector 12.
The extremely efficient sealing of male connector 11 in female connector 12 derives from the internally tapered conical surface 21 formed in connector 12 and the compound tapered conical surfaces 22 and 23 formed externally on connector 11. The angle of taper on all three conical surfaces in this embodiment was selected at 17.5° as indicated on the drawing at 33. This particular angle is preferable with this embodiment because it allows the use of multiple O-ring seals placed side-by-side, which seals are of standard diameters, in one-eighth inch increments of diameter.
The configuration of the compound conical taper on male connector 11 is particularly important to the operation of the invention. The compound taper comprises an interference fit conical section 22 at the extreme end portion of the male connector and separated from the undersize conical section 23 by an undercut annular channel 24. A second channel 25 is also formed on male connector 11 directly behind channel 24 to receive one or more elastomeric O-ring seals 26. The amount of interference of surface 22 in section 15 can be seen in the drawing at 27. This appears as a gap or undersize in the drawing because the connection has not been fully tightened or "drawn up". When the connection is fully drawn up, surfaces 22 and 23 will both be in substantially full contact with the internal taper of section 15.
The provisions of undercut 24 in the tapered portion of section 11 creates a "flex-ring" out of the interference end portion 22 of the male connector. As the connection is drawn up tight by the threading of union 13 on threaded section 15, the interference of end 22 will cause it to flex radially inward and establish the primary metal-to-metal seal as a result of the interference fit. The interference fit does not cause a radially outward flexing of connector portion 15 because of the relative thickness of this section (which gives it a good hoop strength) as well as the reinforcing effect of the outermost section 14 which is located around section 15 and which adds to its overall hoop strength.
The selection of the amount of interference fit 27 between surface portion 22 and section 15 depends upon the size of the connector and the choice of O-rings used. In one particular embodiment, a connector with a two inch internal bore diameter would utilize an interference fit 27 of around 0.008 to 0.010 inches, with O-ring seals of about three-sixteenths (3/16) inch cross-sectional diameter. This provides an effective primary seal and also compresses the multiple O-rings to the optimum compression in groove 25 just as surface 23 contacts the tapered surface 21 of connector portion 15. In the embodiment shown, three elastomeric O-ring seals 26 are illustrated which gives an optimum secondary seal. The inner and outer O-rings 26a and 26c, respectively, provide additional shielding and protection of the middle O-ring 26b. In addition to the three secondary O-rings, an additional O-ring or other-shaped elastomeric annular seal could be placed in channel 24 to provide even additional sealing without requiring further groove machining.
In order to prevent backing-off of the connection once it has been made-up to the proper torque, a unique locking system is utilized between the union 13 and the threaded end of connector 12. This comprises a helical spring 28 having an end loop 29 and an engagement tang 30 at the end of loop 29 protruding axially, parallel with the spring axis. The helical spring is sized in both spring diameter and wire diameter such that it will fit snugly in the helical groove formed by the external thread 15a on threaded section 15. One or more recesses 31 are formed in the axial end wall 13a of union 13 to receive in relatively close-fitting relationship the tang 30 of spring 28.
Spring 28 is located on threaded section 15 with tang 30 engaged in one of the recesses 31 so that as long as the union 13 is turned in a "right hand" or tightening rotation, the spring is expanded radially outward and fits loosely in threads 15a. As soon as the union 13 attempts to move in a loosening or left hand rotation, the spring will be tightened radially, seating firmly in the grooves of thread 15a, and effectively locking collar 13 on connector 12. When it is desirable to remove collar 13, the loop 29 is gripped and pulled to the left to release tang 30 from recess 31, which releases union 13 to be unthreaded from connector 12.
Thus in typical operation, the connector assembly 10, comprising the above described preferred embodiment, is attached to two sections of pipe or steel hose to be connected together. The male portion 11, containing the union 13 rotatably held thereon, is attached at end 11a by means such as welding or attachment by conventional pipe threads to one length of steel hose. The female portion 12 is then attached at end 12a by welding or threads to a second length of steel hose to be connected to the first length. The male and female sections are then joined and union 13 is threaded onto section 15 of connector 12 until tapered surface 22 seats on surface 21. Further tightening can then be achieved by impacting lug 20 thereby further drawing up the connectors until surface 23 seats on surface 21. At this time flex-ring 22 has been flexed radially inward and has formed a positive primary metal-to-metal seal between connectors 11 and 12. Also the measured amount of compression 27 is just sufficient to compress seal rings 26 an optimum amount to effect the secondary seal therein.
When surface 23 reaches abutment with surface 21 the operator will be signalled by a sudden feeling of solid resistance in the union to further tightening thereof and will be informed of the abutment of these surfaces. The engagement of spring tang 30 in recess 31 will occur automatically as union 13 progresses down threads 15a. Spring 28 may be placed on threads 15a prior to engagement of connector 11 in female connector 12. Engagement of tang 30 in recess 31 prevents back-off of union 13 from connector 12 and maintains the primary seal at 22 arising from the interference fit thereof. As previously mentioned, when it is desirable to disconnect the connectors, the springlock can be released by pulling back on spring loop 29 to withdrawtang 30 from recess 31 until union 13 can be released by impact on the opposite side of lug 20 from that used in tightening.
Referring now to FIG. 2 in which a second embodiment of the invention is disclosed in a cross-sectional side view, a connector assembly 110 comprises a male connector 111 and a female connector 112 both of which are generally cylindrical and similar in configuration to those of the first embodiment. A union or collar 13 having hammer lugs 20, threaded end section 14, and annular abutment shoulder 17 thereon is rotatably mounted on male connector 111 and retained by shoulder 116 and retainer ring 18. The coaction of shoulder 17 against shoulder 116 provides the closing force for seating male connector 111 in female connector 112.
In this embodiment both the male connector and the female connector are provided with stepped seating surfaces each of which is a compound tapered conical surface. The male connector surface comprises a first conical surface 122, an inwardly stepped second conical surface 125 separated from surface 122 by shoulder 125b, and a third conical surface 123 separated from surface 125 by shoulder 125a. Shoulders 125a and 125b coact with surface 125 to form a seal receptacle channel.
Female connector 112 has a compound conical sealing surface 121 comprising upper conical surface 121a and lower conical surface 121b, separated by shoulder 120. Shoulder 120 is arranged to align with shoulder 125b to form the upper end of seal channel 125 when the male connector is fully seated in the female connector. The height of shoulder 125b can preferably be made to equal the amount of interference fit between surface 122 and 121a which in one embodiment was around 0.008 to 0.010 inches, or can be set at a higher or lower amount.
A pair of backup rings 124a and 124b are located in the ends of channel 125 and are preferably made of a relatively rigid material such as glass-reinforced Teflon. One or more elastomeric seal members 126a and 126b, such as "O" rings or "radial" seals, are trapped between the backup rings.
Preferably the backup rings and seal rings are selected such that their combined longitudinal length exceeds the length of channel 125 and their radial thickness exceeds the depth of channel 125. Thus when the connector is made up tight, the seal rings will be placed in longitudinal as well as radial compression to provide even better sealing. The interference fit between surfaces 122 and 121a still provides the primary metal-to-metal seal. This compound compression of the seal rings 126a and 126b is particularly advantageous in sealing against very high pressure gas and/or liquid. Other than the seal arrangement of this embodiment, its method of assembly and operation is similar to that previously described for the first embodiment.
Thus the present invention discloses a quick connector which exhibits a metal-to-metal primary seal, an elastomeric secondary seal which is protected by the metal-to-metal seal, and locking means which effectively prevents backing-off at the threaded union but allows quick and easy disengagement when desirable. The primary seal comprises an interference fit flexring on a conical tapered sealing surface on the male connector which is maintained flexed inward in constant seating engagement by the combined hoop strength of the thicker sections encircling it. The resulting connector is extremely resistant to seal blowout, elastomer degradation, and backing-off of the threaded sections.
Although specific preferred embodiments of the present invention have been herein described in the detailed description above, the description is not intended to limit the invention to the particular forms or embodiments disclosed therein since they are to be recognized as illustrative rather than restrictive, and it will be obvious to those skilled in the art that the invention is not so limited. Thus, the invention is declared to cover all changes and modifications of the specific examples of the invention herein disclosed for purposes of illustration which do not constitute departure from the spirit and scope of the invention. | A quick-connection type connector is disclosed for the coupling of high-pressure fluid flow lines, which connector utilizes an externally threaded female portion and a tapered male portion with a rotatable collar mounted thereon. Elastomeric seal means are provided as well as a metal-to-metal seal to protect the elastomeric seal means, and a locking assembly to prevent backing off of the threaded portion. | 5 |
This is a continuation-in-part of application Ser. No. 08/419,097, filed Apr. 10, 1995, and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a water jacketed exhaust pipe that curtails surface exhaust turbulence near the tail end of an inner liner of the pipe thereby preventing the migration of potentially corrosive water and salt back into the inner liner of the pipe. Additionally, the present invention scatters a stream of water exiting the water jacketed exhaust pipe into a spray which is directed into the exhaust gas path thereby causing superior heat exchange from the coolant to the exhaust gas.
2. Description of the Prior Art
Typically marine engines are cooled by water which is pumped from the ocean or lake through a cooler into the engine and then discharged therefrom into a water jacketed exhaust pipe to cool the exhaust system. Preferably, the exhaust is cooled as far upstream as possible to reduce thermal stress on the downstream exhaust system components. However, the prior art method of cooling the exhaust system by injecting a stream of water into the exhaust stream is crude and inefficient. As shown in FIG. 1, the typical arrangement employs a water jacketed exhaust pipe 2 comprising an outer shell 4, an inner liner 6 and a spray ring 8. The pipe 2 is connected to a heat resistant rubber hose or some other standard exhaust conduit. Near the termination of exhaust pipe 2 a circumferential spray ring 8 is employed between the inner liner 6 and outer shell 4. The spray ring 8 is essentially a washer or partition that separates outer shell 4 from inner liner 6 and impedes water from freely exiting the water jacket volume 5 formed between the outer shell and the inner liner. Generally, spray ring 8 contains a plurality of narrow longitudinal passageways 9 from which coolant can exit volume 5 in the form of a spray or stream. However, the coolant stream exiting water jacket volume 5 is generally streamed along only the outer circumference of the volume of exhaust gas flow as shown in FIG. 1. Accordingly, there is a poor mixture of coolant and exhaust gas and thus poor heat exchange. Subsequently, the exhaust system components downstream of the tail end of the water jacketed exhaust pipe 2 unnecessarily absorb heat that could better be transferred to the water. As a result, these downstream components are subjected to higher temperatures and greater temperature cycling than necessary. Moreover, in light of the production of larger marine engines which run at hotter temperatures, marine exhaust systems are already being subjected to hotter temperatures. Accordingly, there is a need for more efficient ways of cooling a marine exhaust system.
An additional shortcoming of the prior art is corrosion. Specifically, it has been discovered that due to the direction of the exhaust gas flow within inner liner 6 a narrow band of turbulence is created near its inner surface 3. As shown in FIG. 2, turbulence T as a suctioning effect opposite the direction of exhaust gas flow. Accordingly, some of the water exiting spray ring 8 will slowly migrate into inner liner 6 along inner surface 3. Additionally, when the boat is run in the ocean the cooling water will contain salt and other impurities that will also migrate into the inner liner. Unfortunately, the hot exhaust gases which contain hydrogen-sulfide and carbon molecules chemically react with the chloride ions produced from the heated salt water to form acids including a mild sulfuric acid which are deposited on the inner surface of liner 6. These acids, over a short period of time corrode the water jacketed exhaust pipe 2. Presently, the only way to prevent this corrosion is to manufacture the inner liner of a highly expensive material that is resistant to acid corrosion.
Accordingly there is a present need for a improved water jacketed exhaust pipe that provides a superior mixture of coolant and exhaust gas and consequently has better heat exchange characteristics. Additionally, there is a present need for a jacketed exhaust pipe termination which clips the turbulence along the inner surface of the inner liner and thereby prevents water spray from migrating into the inner liner where corrosion can occur.
SUMMARY OF THE INVENTION
The water jacketed exhaust pipe termination of the present invention solves the problems encountered by the prior art by the provision of both a first inwardly directed section at the tail end of the inner liner and a second inwardly directed taper at the tail end of the outer shell of the water jacketed exhaust pipe. The first inwardly directed section of the inner liner clips the surface turbulence near the tail end of the inner surface of the inner liner. The second inwardly directed taper near the tail end the outer shell forms a deflection surface which breaks up the water stream and in turn increases heat exchange. Consequently, two significant shortcomings of the prior art have been eliminated without significantly increasing the cost of the pipe.
The first shortcoming eliminated by the present invention is corrosion. Specifically, the first inwardly directed section of the inner liner forms a turbulence barrier that prevents the formation of turbulence near the tail end of the inner surface of the inner liner. In turn, this prevents water and salt from migrating upstream into the inner line and chemically reacting therein to form acids that are deposited on the inner surface of the inner liner. As a result, the prior art shortcoming of destructive acid deposits that corrode the inner line has been eliminated.
The second significant shortcoming eliminated by the present invention is poor heat exchange. The second inwardly directed taper near the tail end of the outer shell forms a deflection surface for water exiting the spray ring. As such, the spray or stream exiting from the spray ring collides with the inner surface of the inwardly directed taper and is broken down into fine water particles which are deflected into the path of exhaust gas flow. Since the water particles have a much greater surface area than the stream of water ejected from the spray ring and since the particles are deflected directly into the exhaust gas path, the cooling water absorbs far more thermal energy per unit volume than the prior art designs.
Accordingly, the new termination makes the muffler pipe more corrosion resistant and increases the surface area of the water that is forced into the exhaust gas path. In turn, this increases the cooling efficiency of the muffler and provides superior thermal protection to the exhaust system components downstream from the water jacketed pipe termination.
It is therefore a principal object of this invention to provide a water jacketed exhaust pipe termination that breaks the stream of water exiting the water jacket into a spray of variably sized water particles.
It is a further object of this invention to provide a water jacketed exhaust pipe termination that clips surface turbulence along its inner liner.
It is yet another object of this invention to provide a water jacketed exhaust pipe termination that prevents water spray from migrating upstream into the inner liner of the water jacketed exhaust pipe.
It is still another object of this invention to provide a water jacketed exhaust termination that prevents corrosion of the inner liner.
It is still yet another object of this invention to provide a water jacketed exhaust pipe that resists acid corrosion without the use of highly expensive acid resistant materials.
It is an additional object of this invention to provide a more efficient water jacketed exhaust conduit that reduces thermal fatigue to exhaust system components downstream of the water jacketed exhaust pipe.
In accordance with these and other objects which will become apparent hereinafter, the instant invention will now be described with particular reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side section view of the prior art;
FIG. 2 is a detailed view of the tail end of the inner and outer liners of FIG. 1;
FIG. 3 is a end view of the present invention; and
FIG. 4 is a side sectional view of the present invention.
FIG. 5 is a side sectional view of an alternate embodiment of the present invention.
FIG. 6 is an end view of an alternate embodiment of the present invention.
FIG. 7 is a side sectional view showing an alternate embodiment of the present invention.
FIG. 8 is a perspective view of the exhaust exit end of the alternate embodiment shown in FIG. 7.
FIG. 9 is a perspective view of the exhaust inlet end of the alternate embodiment shown in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 4, there is depicted a water jacketed exhaust pipe generally characterized by reference numeral 10. The exhaust pipe 10 generally comprises an inner liner 12 having a first inwardly tapered surface 14, an outer shell 18 having an inwardly tapered surface 20 at tail end 16 and a spray ring 16.
In the preferred embodiment both the inner liner 12 and the outer shell 18 and spray ring 16 are constructed from corrosion resistant metal such as stainless steel for example. The outer shell 18 is generally cylindrical in shape and has a diameter greater than inner liner 12. Between outer shell 18 and inner liner 12 is a spray ring 16 or spacer that separates the outer shell from the inner liner, forming a water jacket volume 24 therebetween. Additionally, spray ring 16 prevents water contained in volume 24 from freely exiting the exhaust pipe 10. Preferably, spray ring 16 contains several narrow longitudinal passageways 28 that allow water to pass from volume 24 to cooling turbulent area 22. In that manner, a back pressure is built up within volume 24 thereby forcefully ejecting water through the longitudinal passageways 28 to cooling turbulent area 22. Although the passageways shown are parallel to the elongate axis of the pipe, it is realized they may be in any direction so long as they fluidly connect volume 24 with an external volume outside the exhaust pipe 10.
In operation the exhaust gas flow shown as E in FIG. 4 is directed toward the left out of the water jacketed exhaust pipe 10. As shown, the exiting exhaust gas E causes turbulence T near the inner surface 26 of inner liner 12. Typically, turbulence T is contained within fractions of an inch from inner surface 26. As a result, the turbulence produces a suction effect that normally tends to attract water ejected from passageways 28 of spray ring 16 onto inner surface 26 of the inner liner. However, as shown in FIG. 4, the first inwardly tapered surface 14 at the tail end of inner liner 12 clips the turbulence and as a result inhibits water from travelling backwards along inner surface 26 of the liner.
An additional advantage of the preferred embodiment is its superior heat exchange properties. Specifically, outer shell 18 is provided with a second inwardly tapered surface 20 at its tail end. Preferably, the second inwardly tapered surface 20 is curved such that over its length it curves almost to the radius of inner liner 12. As a result, second inwardly tapered surface 20 is directly in the path of the water stream ejected through the passageway 28 of the spray ring. Accordingly, as the water exits spray ring 16 it forcefully collides into the second inwardly tapered surface 20 and is broken up/separated into fine water particles. As can be seen in FIG. 4, the water particles have a much greater surface area than did the stream of water exiting spray ring 16. Furthermore, the particles upon colliding with surface 20 are redirected into the central part of the exhaust gas flow shown as turbulent cooling area 22. While in the turbulent cooling area the fine water particles are almost immediately converted into steam thereby taking on an immense amount of kinetic and thermal energy. The energy exchange taking place is immense when compared to the amount of energy absorbed by the prior art designs because a phase change takes place. Specifically, since the fine water particles have a much greater surface area as compared with a stream of water they can better mix with the exhaust gases in cooling area 22 and take on enough kinetic and thermal energy to convert from a liquid phase to a gaseous phase. Consequently, a great deal more energy is removed from the exhaust gas than in prior art designs. In turn, this gas is quickly carried through the remaining downstream sections of the exhaust pipe and expelled from the exhaust system. As a result, the downstream exhaust system components which may be fiberglass or rubber are subjected to significantly less thermal stress and are thus are far less prone to melting or other forms of fatigue that could ultimately end in their failure. For example, as shown in FIG. 2 the tail end of the water jacketed exhaust pipe is connected to a heat resistant silicone based rubber hose 30 via a hose clamp 32. Although hose 30 is normally resistant to high temperatures it has a longer life expectancy when subjected to lower temperatures. Accordingly, another advantage of the present invention is reduced thermal fatigue on exhaust system components downstream from the tail end of the water jacketed exhaust pipe 10.
It is realized that neither the first or second inwardly tapered surfaces 14 and 20, respectively, have to be curved as shown in FIG. 2. Rather, either or both surfaces may be in the form of a cone or any other shape that is generally directed inwardly. Furthermore, the use of the term water in this application is meant to include sea water, lake water and in general any body of water that marine vessels may be operated within.
An additional shortcoming of the prior art is eliminated due to the superior heat exchange properties of the present invention. Typically, a marine engine of an average size boat will pump 90-100 gallons per minute when running at full bore or cruising speed. Accordingly, there is a great deal of water to cool both the engine and exhaust system when the engine is running at this speed. However, when the engine is idling, it is typical that only 15 gallons per minute will be pumped through the exhaust system. In the prior art designs, 15 gallons per minute does not extract a great deal of heat from the exhaust and thus, the exhaust system can be overheated. However, in the present invention, adequate coating still takes place, even when the engine is running at idle and only pumping 15 gallons of water per minute due to the higher efficiency of heat transfer from the exhaust gas E to the water.
It is envisioned that this invention is applicable to both water jacketed pipe and dry pipe. Water jacketed pipe refers to a type of pipe wherein the entire pipe is double-walled from the engine to the tail end and water is communicated from the engine directly into the space between the inner liner and outer shell. On the other hand, a dry pipe is a single-walled pipe wrapped with insulation, wherein only a short section at the very tail end of the pipe contains a double-walled section. In this case, a water can is welded onto the dry pipe and water can be pumped into the tail end of the pipe to be mixed with exhaust in the same manner explained for the water jacketed pipe.
ALTERNATE EMBODIMENT
In an alternate embodiment, as shown in FIGS. 5-9, the inner liner 12' extends beyond the outer shell 18'. Spray ring 16' is angled between outer shell 18' and inner liner 12' so that passageways 28' direct water flow from volume 24' onto inner surface 20' of outer shell 18'.
Directing the water flow from passageways 28' directly at the outer shell 18' intensifies the effect of the inwardly tapered surface 20'. The water fans out from passageways 28' and collides with outer shell 18' and inwardly tapered surface 20' and is further broken up/separated into fine water particles. A portion of the water particles are deflected back onto the exterior surface 27' of the inner liner 12' thereby providing a uniform film of water near the termination of the exterior surface 27' of inner liner 12'. The uniform film of water absorbs heat from inner liner 12', and under certain operating conditions will almost instantaneously flash to steam thereby beginning the cooling process even prior to entering the turbulent cooling area 22'.
Passageways 28' in spray ring 16', shown in FIGS. 5-8, are fewer, but larger in diameter than passageways 28 in spray ring 16, shown in FIG. 4. Fewer large diameter passageways increases water flow and the cooling effect is thereby increased. Passageways 28' are spaced such that the streams of water fan out therefrom such that streams from adjacent passageways 28' intersect after contacting outer shell 18' thereby causing a portion of the water to deflect away from outer shell 18' and onto the outer surface 27' of inner liner 12'. Accordingly, it is important that spray ring 16' is spaced a sufficient distance from the termination of the inner liner 12' and outer shell 18', and that passageways 28' are spaced and angled toward outer shell 18' so as to project fanning streams of water such that adjacent streams intersect after contacting outer shell 18' causing a portion of each water stream deflect onto the outer surface 27' of inner liner 12'. In addition, a portion of the water disperses into a substantially uniform film on the inner surface of outer shell 18' and is dispersed as fine particles by inwardly tapered surface 20' into the central part of the exhaust gas flow 22'
Inner liner 12' extends beyond the end of outer shell 18' into the turbulent cooling area 22'. As in the first embodiment, the inwardly tapered surface 14' of inner liner 12' clips turbulence and thus inhibits water from traveling backward along inner surface 26' of liner 12'. Having inner liner 12' extend into the turbulent cooling area 22', further reduces water flow back along inner surface 26' of the liner.
In an example of supplying water to the present invention, as shown in FIGS. 7-9, water will enter volume 24' via fitting 50' and inlet pipe 48'. Fitting 50' will attach via fitting 52' to water pipe 54'. Water entry in this manner is intended as an example and is not intended to restrict the invention only this manner of water entry.
The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious modifications will occur to a person skilled in the art. | A water jacketed exhaust pipe comprising an inner liner, an outer shell, and a spray ring. The inner liner includes an internally tapered section which clips the turbulence that occurs along the inner walls of the liner. As a result, fluid expelled from the spray ring will not migrate into the inner liner where it can cause severe corrosion. The inner liner is longer than the outer shell. The outer liner includes an internally tapered section which scatters the stream of water expelled from the spray ring and further redirects water onto the inner liner and into the center of the exhaust path. The redirected water particles are easily vaporized and in the process, extract a significant amount of heat from the exhaust system. | 5 |
RELATED APPLICATIONS
This is a continuation-in-part of application Ser. No. 13/135,917 filed Jul. 18, 2011 of Smith et al.
FIELD OF THE INVENTION
The present invention relates to a process for producing modified polyvinyl alcohol film or fabric having a surface layer which is coalesced and has a surface porosity at a low desired level, more particularly, the process relates to applying heat and pressure to the film or fabric so as to increase the moisture on the surfaces which is held by the film or fabric and to coalesce the surface fibers and reduce the porosity of the surface.
BACKGROUND OF THE INVENTION
The prior art has recognizes uses for polyvinyl alcohol compositions in the manufacture of water soluble useful articles. For example, U.S. Pat. No. 3,413,229 which is incorporated herein by reference, teaches the production of water soluble bags or pouches for which packets or the like are produced containing such materials as detergents, bleaches, insecticides, medicinals, chemicals, dyes, pigments, industrial additives and other materials. It is taught that the contents of the packets are dispersed merely by dropping the packets into water whereupon the bags dissolve and release their contents into aqueous dispersions. However, the referenced patent teaches the production of such films which are both hot and cold water soluble.
U.S. Pat. No. 3,859,125, which is incorporated herein by reference, teaches the production of layered articles which include coatings of polyvinyl alcohol. The subject reference teaches coating polyvinyl alcohol on a paper membrane whereby it is taught that the coated paper is soluble in either high or low temperature water. Similarly, U.S. Pat. No. 4,343,133 teaches the coating of polyvinyl alcohol onto a non-woven fiber sheet impregnated with lattices of polyvinyl acetate in the manufacture of a pre-moistened towelette which can be disposed of by flushing in plain water without danger of clogging a plumbing system.
Both U.K. Patent No. 1,187,690 and Japanese Patent No. 72041741, which are incorporated herein by reference, teach the production of stand alone polyvinyl alcohol films which are water soluble. The U.K. patent teaches the production of hospital bags and packaging material for such products as detergents and agricultural chemicals while the Japanese patent teaches the use of polyvinyl alcohol films to make laundry bags which dissolve releasing soiled garments contained therein. However, neither reference teaches the unique films of the present invention which can be configured into useful garments and like materials.
SUMMARY OF THE INVENTION
The process comprises passing a film of polyvinyl alcohol (PVOH) having a moisture content of at least 5-10% through a pair of calendar rolls with a heated calendar role to provide increased moisture at the surface of the PVOH film to coalesce the surface and lower its porosity.
Advantageously, the unheated opposing calendar roll has a softer surface than that of the heated calendar roll.
According to a further embodiment of the invention both calendar rolls can be heated so that both surface of the PVOH film are coalesced and have a reduced porosity.
It is a general object of the invention to provide a process for modifying at least one surface of a PVOH film based on the moisture content on its surface so to alter the surface and provide a reduced porosity.
It is another object of the invention to provide a process for lowering the surface porosity of spunlaced non woven PVOH fabric while not detracting from its other desirable properties such as strength and abrasion resistance.
It is a further object of the invention to modify a surface of a PVOH non woven fabric by controlling the moisture content of the non woven PVOH fabric before processing it through a heated calendar roll.
These and other objects and advantages will be noted by a reading of the Preferred Embodiments of the invention and the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic of the apparatus used in the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The fabric contains at least 5-10% by weight water under normal indoor conditions when received and is maintained in this state. These conditions are normal air conditioned/relative humidity in most modern mills. There needs to be certain the percentage of contained moisture in order to achieve repeatable results under consistent process settings as the fabric is hot calendared. This moisture content of at least 5-10% is sufficient to reproducibly provide increased moisture at the surface of the PVOH film or fabric so that the hot calendar roll with pressure forces the coalescing of the surface fibers to restrict the surface porosity to the low desired level. No steam is required or extra water is required under these conditions to achieve the degree of coalescing of the fibers and the lowering of the porosity.
In order to make the process less susceptible to changes in the fabric moisture content, the calendar rolls should be composed of a heated metal roll, preferably steel, and an unheated counter roll with a surface coated or covered with an appropriate high melting hard tough polymer film such as silicone rubber polyamide, Teflon or polyurethane. The surface of this polymer film or coating will result in a wider nip print resulting in an increased contact area between the heated metal and coated rolls. The increased contact between the two rolls will result in increased contact between the heated roll and the fabric which will improve the heat and pressure transfer of moisture to the surface of the fabric. Additionally, by employing a softer, unheated opposing or counter roll will result in a small difference in the differential stretch between the two sides of the fabric which improves the quality (controlled reduced porosity) of the film formation on both sides of the fabric surface. The softness of the coated roll can be altered to change the stretch differential of the surface of the fabric and the reduced porosity obtained of the fabric, and to modify the properties of the resulting processed fabric. In essence each film coating on the roll and the thickness of that coating will determine a different foot print on the surface of the PVOH fabric surface.
Variations in the process can be readily and practically accomplished by heating both rolls, by heating and coating both rolls, by using the preferred configuration of heating the uncoated steel roll alone and not heating the opposing coated roll, and varying the pressure and varying the line speed. The process is very flexible and small adjustments in line speed, roll pressure, roll temperature and diameter of the rolls allow for variations in moisture content of the PVOH fabric and allows fine tuning of the porosity of both of the fabric surfaces to achieve the desired air permeation properties.
Once the PVOH fabric exits from the calendar roll, it must be quickly cooled so as not to disturb low porosity surface film which has been formed. The fabric is preferentially passed over a chill roll and not distorted until the fabric is cool and the surface has been hardened. Minimum tension is used after the calendar roll.
Further variation can be accomplished by increasing the moisture content of the initial fabric by conditioning the fabric in a humid environment so that the moisture content is greater than the 5-10% by weight of water which it normally contains, for example, about 11-15%. To modify the surface on the other side, the fabric from the take-up roll can be reversed and passed a second time through the apparatus.
The initial fabric to be treated can comprise polyvinyl alcohol or it can be laminated with another thermoplastic such as a polyolefin, preferably, polyethylene.
Polymer or sheet materials useful in practicing the present method comprise polyvinyl alcohol with or without acetyl groups, cross-linked or uncross-linked. The garments are comprised of polyvinyl alcohol homopolymer that has been highly crystallized by post drawing or heat annealing. Ideal for use in the present invention would be a highly crystallized, at least approximately 98% saponified polyvinyl acetate. Commercially, polyvinyl alcohol sold under the trademark Vinex 1003™ and 1002™ by Air Products could be used herein. Useful fibers are typically 0.4 to 7 mils. A commercially available product for use in the present invention is either type T-B (VEE 1290) or type T-5 (VPB 101) which are each available from Kuralon as its PVA fiber. This material is sold in 44 mm lengths. The T-B product is sized at 1.2 denier while the T-5 product is sold in 38 mm staple lengths of 1.5 denier.
The fabric useful in practicing the present invention can be constructed by any well known technique for making woven, non-woven, knitted or otherwise formed fabric. Such non-woven techniques useful in practicing the present invention include spun bonding, melt blowing or wet laying, hydro entangling with cold water and/or thermally bonding with 30-70% of the surface melted to form. When products are configured of sheets of suitable thermoplastic material, the sheets are approximately 1 to 6 mils in thickness and more preferably 1 to 3 mils in thickness and most preferably approximately 1.5 mils in thickness. Suitable non-woven fabric or sheets are approximately from 15 g/yd.sup.2 to 200 g/yd.sup.2 in weight and more preferably from 20 g/yd.sup.2 to 70 g/yd.sup.2 and most preferably from 25 g/yd.sup.2 to 80 g/yd.sup.2.
As noted previously, polymer or sheet material useful in practicing the present invention is comprised of polyvinyl alcohol with or without acetyl groups, cross-linked or uncross-linked. It is proposed that the polyvinyl alcohol be substantially fully hydrolyzed, that is, having 98% or greater hydrolyzed acetyl groups.
For the sake of adequate mechanical strength, in some cases the polyvinyl alcohol-based sheet material should have a degree of polymerization of at least 700 and no greater than approximately 1500. Ideally, such materials should have a degree of polymerization of approximately 900 and be substantially crystallized.
To enhance the manufacture of suitable polyvinyl alcohol resin-based materials, suitable quantities of a plasticizer may be necessary. It is contemplated that up to 15% (wt.) of a suitable plasticizer such as glycerin or polyethylene glycol may be employed to assist in providing a smooth melt extrusion from the polyvinyl alcohol-based pellets.
It was found that the manufactured fabric for use as disposable medical garments displayed nearly identical physical properties similar to fabric manufactured from polyethylene, polyester and polypropylene. However, the fabric manufactured was unaffected by cool or warm water (23°−37° C.) but when exposed to hot water (80°−90° C.), immediately dissolved.
The incorporation of a water repellent on or within the polyvinyl alcohol film or fabric is quite a useful adjunct to minimize surface attack by liquid moisture at a temperature lower than that at which solubility occurs. It has been found that even with polyvinyl alcohol films and fabrics which become water soluble only at elevated temperatures, when exposed to water, the surface of such material tends to take on a slick “feel” and the use of water repellents tends to minimize this effect. Suitable repellents include fluorocarbons offered by the 3M Co. sold under its trademarks FC 824 and 808 . These materials are useful in the range of between 0.1 to 2.0% (wt.) based on the weight of the polyvinyl alcohol polymer.
Antimicrobial agents can add to the surface particularly for medical applications such as gowns, drapes, etc. Antimicrobials include GERM PATROL® sold by Germ Patrol, LLC, silanes, silver or copper antimicrobials, and the like.
As shown in FIG. 1 , an apparatus ( 10 ) used in fabricating the modified surface of the PVOH comprises a fabric roller ( 11 ) wherein the fabric ( 12 ) is passed through calendar rollers ( 13 , 13 1 ). Roller ( 13 ) is a heated metal roller, preferably steel, and counter roller ( 13 1 ) is an unheated roller having a surface coating ( 14 ) of a high melting polymer film such as a polyamide, TEFLON®, polyurethane and silicon rubber wherein the surface is modified by the contact between the two rollers ( 13 , 13 1 ) to increase the moisture at the surface to coalesce the fibers on the surface. The temperature of the heated roller ( 13 ) is generally about 120° to 190° C. The modified fabric then passes under a sprayer ( 20 ) which can spray an additive such as a water repellant, dye, anti-stat agent, etc. The fabric is then passed under chill rollers ( 16 , 16 1 ) which are cooled by refrigerated water and then onto the take-up roller ( 17 ).
To modify the other surface of the PVOH fabric the process can be run a second time or the apparatus can be modified by providing a heated roller for the other side.
The following Example is merely illustrative of the invention and modifications are within those skilled in the art.
EXAMPLE
A series of trial runs were made using a 600 mm rolls of PVOH having a length of 600 mm with a thickness which varied at 0.52 mm to 0.45 mm with an outside moisture reading of 6.50%.
Tests 5 and 6 were run on the same apparatus and tests 8 and 9 were run on the same apparatus.
The results are as follows:
PROCESS DATA
FIRST PASS
Test No.
Set Temp
Roll Temp
Air Perm
Thickness
Speed
Pressure
1
145° C.
130° C.
87.93
6.2
mil
20.2 m/min.
200 N/mm
2
145° C.
130° C.
87.93
6.2
mil
20.2 m/min.
200 N/mm
3
145° C.
138.6° C.
50.0 m/min.
250 N/mm
4
170° C.
147° C.
50.0 m/min.
250 N/mm
5
190° C.
161° C.
26
cfm
5.4
mil
N/A
N/A
6
190° C.
161° C.
50.1 m/min.
250 N/mm
7
190° C.
170° C.
5.58
cfm
3.81
mil
8
Preheat
170° C.
170.0
cfm
4.15
mil
9
Preheat
170° C.
7.55
3.87
ml
10
190° C.
170° C.
6.82
3.42
mil
SECOND PASS (reverse roll sequence)
Test No.
Set Temp
Roll Temp
Air Perm
Thickness
1
145° C.
130° C.
18.0
cfm
3.87
mil
2
145° C.
130° C.
54.1
cfm
4.21
mil
3
150° C.
130° C.
4
170° C.
147.0° C.
24.6
cfm
5.4
mil
5
N/A
N/A
N/A
N/A
6
190° C.
161° C.
23
cfm
3.6
mil | The present invention provides a process for modifying the surface of a polyvinyl alcohol film or fabric by applying heat and pressure to the film or fabric to increase the moisture on the surface which is held by the fabric and to coalesce the surface fibers and reduce the porosity of the surface. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application incorporates by reference and claims priority to Polish Patent Application No. P.402427 filed Jan. 14, 2013.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to folding stairs, particularly light weight wooden stairs designed for installation in the ceiling of a building or house, wherein the stairs open downward and unfold toward the inside of the room located under the ceiling. The present system may find applications in the building industry, especially for designing entries to lofts and attics.
[0003] Folding stairs with hinged mechanisms with variable axis of rotation are known for example the hinge disclosed in Polish patent No. 199927, equipped with a flap which closes the opening in the frame from underside. As the stair sections are fastened to the flap, it also plays a role of a supporting structure for the stairs and, to perform this function, it must be adequately reinforced to withstand loads generated by both own weight of stair sections and the weight of persons using the stairs.
SUMMARY OF THE INVENTION
[0004] The present disclosure provides a system of light weight folding stairs, especially lightweight wooden stairs, designed for installation in the ceiling of a building. For example, the light weight ladder-type stair system may be opened downwards and unfolded towards inside the room located under this ceiling. A frame may be installed in an opening in the ceiling, wherein a set of ladder-type stair sections mutually connected by hinges may be unfolded to create a linear ladder. At least one ladder-type stair section is connected to a flap that fits within the opening, and may be hingedly opened from the frame to allow access to the stair sections. The first stair section is connected in a pivoting manner with the frame by means of hinge holders fastened to inner wall of frame, and during unfolding of the stairs the axis of rotation of first stair section retains its position with respect to the frame.
[0005] The flap is suspended from the first section of stairs section by at least two pairs of connecting rods which, together with this first section of stairs and the flap itself, form a four-bar linkage. The connecting rods by which the flap is suspended are fixed to it by hook-type holders, each of them being equipped with a bearing seat for a journal fixed in the connecting rod by which the flap is suspended. The mounting access to this seat is closed by the insert having the surface complementing the seat contour and is mounted in snap-locking manner in the body of hook-type holder. The bearing seat of hook-type holder is through-open from both sides, whereas the journal of connecting rod by which the flap is suspended terminates with the flange with diameter greater than the diameter of seat. In such arrangement the lateral movements of the journal in hook-type holder are restricted by abutting the journal flange or the connecting rod against one or the other side wall of hook-type holder.
[0006] Further, in the insert which closes the mounting access to the hook-type holder seat, the bearing surface opposite the complementing surface rests, in closed state, on the supporting protrusion in the body of this hook-type holder.
[0007] The insert which closes the mounting access to the hook-type holder seat is movably connected with the body of this hook-type holder through the elastic connecting member. This member constitutes a whole with the hook-type holder body and the insert. The latch connected with the insert and locking it in closed position has a catch located on opposite side of the supporting protrusion with respect to the insert. The seat mating with the catch is located in the supporting protrusion on its side opposite with respect to the insert. The latch also has an elastic connecting member which forms a movable connection between the catch and the insert. This elastic connecting member constitutes a whole with the insert and catch of the latch.
[0008] The sections of ladder-type stairs are connected using hinges located in joints between subsequent sections, on the top or bottom of stringers of these stair sections. The first section which in unfolded state of stairs is located uppermost and above all other sections is joined with the second section by top-axis hinges having the axis of rotation at the upper surface of stringers of both adjacent stair sections. The next sections of stairs, i.e. the second and the third section, are connected by means of low-axis hinges having the axis of rotation at the lower surface of stringers of both adjacent stairway sections.
[0009] The first section of stairs, on its end opposite to the joint with the second segment, is connected with the frame by hinged holders secured to the inner wall of the frame. In the pair of connecting rods located closest to the hinged holders at least one rod is provided in the form of double-arm lever, connected in its central part with the first section of stairs in a rotating manner. The arm of this lever located opposite the flap is connected through the pull rod with the frame, preferably with hinged holder mounted on it. In the folded state, where all sections of stairs are hidden inside the frame, the flap closes the frame and the connecting member in the form of double-arm lever pulls the flap against first section of stairs. During opening of the stairs to the room under the attic, the flap together with stair sections opens downwards and then moves away of the first section of stairs, thereby increasing the clearance for user's feet.
[0010] The first section of stairs is suspended from the frame also by means of a pair of spacer connecting members located on both sides of this section, at the outer side of each stringer. The purpose of these spacer connecting members is to limit the stair opening angle. Preferably, each spacer connecting member consists of two flat pull rods connected with each other by means of pivoting joint. Lower ends of these spacer connecting members are connected to transversal supporting beam which protrudes from both sides of first section of stairs beyond the stringers of this section. This supporting beam is positioned in the recesses extracted in lower surfaces of stringers of first stair section, particularly near the half of length of this section. The supporting beam is equipped with lugs which connect it with stringers of first section of stairs.
[0011] Further, the stairs are equipped with tension springs that assist raising of stairs during their closing and attenuate dropping of stairs, causing them to fall more gently during opening. Lower ends of these springs are secured to movable components of stairs near the points where the supporting beam connects with spacer connecting members. Preferably, lower ends of these springs are fastened to the ends of supporting beam, near the points where the beam joints with spacer connecting members. Upper ends of tension springs are secured to extension arms protruding upwards from frame corners. Preferably, the tension force of springs is so adjusted that it exceeds the weight of sections of stairs and the flap and, therefore, presses the flap against the frame. Should the springs with smaller tension be used, the flap is equipped with additional lock retaining it in closed position.
[0012] The present disclosure provides a folding stair system for installation in a ceiling, wherein the stair system folds down from an opening in a ceiling, the system comprising a flap configured to fit flush within the opening in the ceiling, wherein the opening is defined by a frame, wherein the flap is hingedly connected to the frame. The system also includes at least two ladder-type stair sections hingedly connected together, wherein the ladder-type stair sections convert between a folded position and a ladder position, wherein the folded position the ladder-type sections are foldably stacked upon one another, wherein the ladder position the ladder-type sections unfolded into a linear ladder.
[0013] The system includes a hook-type holder connecting a ladder-type stair section to the flap, wherein the hook-type holder includes a body including a base and a hook, wherein the base is in contact with the flap, wherein the base includes a protrusion defining a catch seat space between the base and the flap, wherein the hook extends above the base and curves over the base, wherein the hook includes a top surface and a bottom surface. The hook-type holder also includes a latch extending from the top surface of the hook, wherein the latch includes an insert and a catch.
[0014] The system also includes a cylindrical journal inserted into a journal seat space defined by the bottom surface of the hook, wherein the cylindrical journal is connected to a first end of a connecting member, wherein a second end of the connecting member is attached to a first end of a pull rod, wherein a second end of the pull rod is connected to the frame.
[0015] The hook is configured to move between an open position and a closed position. In the closed position, the insert is held in contact with a surface of the cylindrical journal when the catch is in the catch seat space and engaged with the protrusion of the base.
[0016] In an example, the system also includes at least one cylindrical flange attached to an outer surface of the cylindrical journal, wherein a diameter of the cylindrical flange is greater than a diameter of the cylindrical journal, wherein the cylindrical flange rests flush against an outer surface of the hook.
[0017] The insert may be movably connected to the latch by an elastic connecting member. The catch may be connected to the insert by an elastic connecting member.
[0018] The system may further include a hinged holder, wherein the hinged holder is connected to an inner wall of the frame, wherein the second end of the pull rod is connected to the hinged holder.
[0019] In an example, the system may also include a pair of spacer connecting members pivotally connected to each other, wherein a first end of a first spacer connecting member is connected to the frame, wherein a second end of the pair of spacer connecting members is connected to the flap.
[0020] The second end of the pair of spacer connecting members may be connected to a transversal supporting beam attached to the flap, wherein the supporting beam is attached to a first ladder-type stair section. The supporting beam may be positioned in a recess in the first section of stairs.
[0021] The system may also include a tension spring connecting the first ladder-type stair section with the frame. The tension spring may be connect the spacer connecting member to the frame.
[0022] In another embodiment, the folding stairs are designed for installation in the ceiling of a building, for example, opening downwards together with a flap designed for closing the opening in the building ceiling from the underside and unfolding into the room located under the ceiling. The folding stairs include a plurality of ladder-type stairs sections connected to each other by hinges located in individual joints of consecutive stairs sections at upper and lower ends of stringers of the consecutive stairs sections, wherein the plurality of stairs sections including a first stairs section and a second stairs section.
[0023] The first stairs section, which in an unfolded state, takes the highest position amongst all of the stair sections, is pivotally connected with a frame and an axis of rotation between the first stair section and the frame remains unchanged regardless of the position of the folding stairs. The second stairs section is connected to the first stair section by at least one high-axis hinge having an axis of rotation at an upper section of the stringers of both of the first stairs section and the second stairs section.
[0024] The flap is suspended from the first stairs section by at least two pairs of connecting members that together with the first stairs section and the flap form a four-bar linkage. The connecting members suspending the flap are connected with the flap by hook-type holders, each hook-type holder including a bearing seat engaging a journal seated in one of the connecting members on which the flap is suspended, wherein the mounting access to the bearing seat is closed by an insert including a surface complementing the bearing seat and fastened to the hook-type holder by a latch.
[0025] The bearing seat of each hook-type holder may be open at both sides of the hook-type holder forming a through opening and the journal of the connecting member that suspends the flap ends with a flange having a diameter greater than a diameter of the bearing seat. A bearing surface of the insert that is opposite to the surface complementing the bearing seat may rest, when the hook holder is in a closed state, on a supporting protrusion in a body of the hook-type holder
[0026] An elastic connecting member may movably connect the insert with the body of the hook-type holder. An elastic connecting member may connect the catch to the insert.
[0027] In an example, the latch may include a catch located at the opposite side of the supporting protrusion from the insert and a seat mating with the catch is located in the supporting protrusion.
[0028] The first stairs section may be connected to the frame by hinged holders secured to an inner wall of the frame, wherein the pair of connecting members located closest to the hinged holders on which the flap is suspended includes at least one double-arm lever including a first arm pivotally connected in a central area of the first stairs section and a second arm connected to the frame by a pull rod.
[0029] In another example, the first stairs section is suspended from the frame by a pair of spacer connecting members, each spacer connecting member including two flat pull rods connected pivotally to each other by a pin.
[0030] The spacer connecting members may be connected to a transversal supporting beam located near the half-length of the first stairs section and extending wider at both sides than the stringers of the first stairs section.
[0031] A plurality of tension springs may connect the first stairs section with the frame, wherein the tension springs are secured to movable components near where the supporting beam connects with the spacer connecting members.
[0032] An advantage of the present system is that because a section of stairs, not a flap, is used as the supporting structure connecting the moving elements with the frame, the flap itself is lighter and more convenient in use as compared with known solutions.
[0033] Another advantage of the present system is that the hook-type holders allow installing the frame in a ceiling opening without the flap, which can be easily and quickly attached during final stage of assembly.
[0034] Yet another advantage of the present system is the positioning of a supporting beam in recesses extracted in the first section of stairs in order to reduce the overall dimensions of folded stairs, thereby facilitating transportation.
[0035] Additional objects, advantages and novel features of the examples will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following description and the accompanying drawings or may be learned by production or operation of the examples. The objects and advantages of the concepts may be realized and attained by means of the methodologies, instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar element.
[0037] FIG. 1 is a perspective view of an embodiment of the ladder-type stairs in an unfolded state and ready for use.
[0038] FIG. 2 is a side view of the first and second segment of ladder-type stairs in an unfolded state along with cross-sectional view of suspended flap.
[0039] FIG. 3 is a perspective view of the hook-type holder in open state, as seen from the side of the insert and supporting protrusion.
[0040] FIG. 4 is a perspective view of the hook-type holder in open state, as seen from the side of foot securing it to the flap.
[0041] FIG. 5 is a vertical cross-section view of an example of the connection between the flap and hook-type holder in open state, wherein the cross-section is taken through the bolt connecting these elements.
[0042] FIG. 6 is a perspective view of a connection between the flap and hook-type holder in closed state in vertical cross-section through the seat, insert and latch.
[0043] FIG. 7 is a perspective view of the first stair section connection with the frame.
[0044] FIG. 8 is a perspective view of the connection between supporting beam and first section of stairs, together with the pull rod.
DETAILED DESCRIPTION OF THE INVENTION
[0045] The main assembly of folding stairs is a set of ladder-type sections 1 consisting of the first section 11 , the second section 12 and the third section 13 . Each of those sections contains two stringers 14 , the left one and the right one, with steps 15 fitted between them, and the individual sections are connected with each other by means of hinges secured to the end portions of stringers 14 .
[0046] The first section 11 and the second section 12 of stairs are joined with each other by means of high-axis hinges 16 with the axis of rotation located at upper surface of stringers 14 , whereas the second section 12 and the third section 13 are joined with each other by means of low-axis hinges with the axis of rotation located at lower surface of stringers 14 .
[0047] The stairs have the frame 2 consisting of two longitudinal walls 21 and two transverse walls 22 . The frame is seated in the ceiling above the room to which the stairs are to be unfolded for use. First section 11 of stairs in unfolded state is located in the upmost position, second segment 12 is a middle one and third segment 13 is located in the lowest position and rests against the floor of the room under the ceiling. In the stairs in folded state the segments 12 and 13 rest on the first segment 11 , and the whole set of segments is hidden inside the frame 2 .
[0048] The first segment 11 is connected by its stringers 14 with transverse wall 22 of the frame by means of two hinged holders 3 , each of them consisting of angle bar 31 and stringer-adjacent strip 32 connected by means of the pin 33 located at lower end of angle bar 31 . Both hinged holders 3 are so positioned that the pins 33 belonging to them are concentric, thus forming common axis of rotation of the first section 11 and other two sections with respect to the frame 2 , while the axis of rotation of those sections does not change during folding or unfolding of stairs. The angle bar 31 and stringer-adjacent strip 32 are secured by means of bolts 34 to transverse wall 22 of the frame and to stringers 14 of the first section 11 , respectively.
[0049] Stairs are also equipped with flap 4 which closes the opening in frame 2 from underside when the set of ladder-type sections of stairs 1 is in folded state. The flap 4 is suspended from the first segment 11 of stairs by two pairs of connecting rods and connecting rods of each pair are located at both sides of the first stairs section 11 , outwards of stringers 14 of this section. Next to the hinged holders 3 the double-arm connecting members 41 are located and near opposite end of the first stairs section 11 the straight connecting members 42 are installed. The upper end of straight connecting member 42 is joined in articulating manner by the bolt 43 with the first stairs section 11 .
[0050] Low ends of double-arm connecting member 41 and straight connecting member 42 are secured by means of hook-type holders 5 to the flap 4 . The hook-type holder 5 has the body whose base contacts with the flap 4 , and above this base the hook 51 is provided with seat 52 extending through it and having the surface in the form of cylindrical sector. In the seat 52 the cylindrical journal 44 of the double-arm connecting member 41 or the straight connecting member 42 is located which abuts on the side surface of hook 51 . The journal 44 is attached to the connecting member 41 or 42 in non-detachable manner and its free end has the cylindrical flange 45 mating with under-flange surface 53 of hook holder 5 . The hook holder 5 , on the side which after mounting the holder on flap 4 becomes the side outer with respect to the stairs 11 , has the fixing foot 54 with oval bore 54 a for the bolt 35 with nut attaching the holder to the flap 4 .
[0051] The mounting access to the seat 52 is closed by the insert 55 with a part of the surface shaped in the form of cylindrical sector complements the bearing 55 a. The opposite bearing surface 55 b of the insert 55 rests in closed state on supporting protrusion 56 in the hook holder body 5 , and more precisely, on the supporting surface 56 a of this protrusion.
[0052] Also, the hook holder 5 has the latch 57 which keeps the insert 55 in fixed position when the hook holder is closed. In the latch the catch 57 a is provided, connected with the insert 55 by means of an elastic connecting member 57 b constituting a whole with the insert 55 and the catch 57 a of the latch. The catch 57 a of the latch 57 , positioned on the side of supporting protrusion 56 which is opposite with respect to the insert 55 , in closed state engages into the seat 56 b in this supporting protrusion. The latch 57 also has the releasing groove 57 c for the tool, e.g. a screwdriver, used for removing the catch 57 a from the seat 57 b.
[0053] The insert 55 is connected, by means of movable connection, with the body of hook-type holder 5 through the elastic connecting member 58 which constitutes a whole with hook holder 5 and the insert 55 . The hook holders secured to the flap 4 are so positioned that their hooks 51 are directed outwards. In such arrangement the hooks 51 transmit the highest component forces present in connecting members 41 and 42 and caused by the flap weight. Due to asymmetric position of the fastening foot 54 with respect to the hook 51 and the seat 52 , the set of four hook holders 5 consists of two left-side holders and two right-side holders, secured to the flap 4 crosswise, i.e. along the diagonal.
[0054] In the mechanism designed for suspending the first stairs section 11 and the flap 4 the double-arm connecting member 41 , in its central area, is connected with stringer-adjacent strip 32 of hinged holder 3 by means of central pin 46 , and the upper end of double-arm connecting member 41 is connected with the upper part of angle bar 31 of hinged holder 3 by means of pull rod 47 . Both ends of pull rod 47 are connected, by means of pins 48 forming the articulated joints, with parts mating with this pull rod.
[0055] The first section 11 of stairs, the double-arm connecting member 41 on its part between central pin 46 and the hook holder 5 , the straight connecting member 42 and the flap 4 form a four-bar linkage mechanism, whose motion is caused by action of the pull rod 47 and upper part of double-arm connector 41 which, together with the angle bar 31 and stringer-adjacent strip 32 , form a four-bar linkage mechanism also. When placing the set of ladder stairs inside the frame 2 , in the final phase of closing this set of stairs and placing it in rest position, both four-bar linkages move the flap 4 into position adjacent to the frame 2 . Since the distance between flap 4 and first stairs section 11 is minimal, the whole structure is compact, facilitating transportation and storage of the stairs. With stairs in open position, including open for use, both four-bar linkages move the flap 4 to the position distant from the first segment 11 by the distance enough to ensure proper space for feet of person stepping on the steps 15 of this stairs section.
[0056] Apart from being connected with the door frame 2 by means of hinged holders 3 , the first stairs section 11 is also suspended from the frame by means of spacer connecting members 6 located at both sides of this section, on the outer sides of its stringers 14 . The spacer connecting member 6 consists of two flat pull rods, i.e. the upper pull rod 61 and lower pull rod 62 , joined together by means of joint 63 . The ends of both lower pull rods 62 are connected to the transverse supporting beam 7 which extends beyond the stringers 14 of this first stairs section 11 at both sides of this section. At the ends of the supporting beam the bends are provided which form the supporting lugs 71 which, by means of pins 72 , are connected with lower pull rods 62 of both spacer connecting members. Upper end of spacer connecting member 6 is secured to the frame by means of side holder which is bolted to the longitudinal wall 21 of the frame 2 .
[0057] The supporting beam 7 is located near the half-length of the first stairs section 11 and enters the recesses 18 formed in lower surfaces of stringers 14 of this section. By placing the beam in recess it is possible to minimize the distance between the flap 4 and the first stairs section 11 when the stairs are folded in closed position. The supporting beam has lugs 73 , along with bolts 74 , fastens the beam to stringers 14 of the first stairs section 11 at its right and left side. The folding stairs are also equipped with two tension springs 7 which assist rising of stairs during their closing and attenuate dropping of stairs during their opening. Lower ends of these springs are secured to lower pull rods 62 of spacer connecting member 6 near the point at which this pull rod connects with the supporting beam 7 . Upper ends of tension springs 8 are fitted by means of coil chain section to outriggers 81 which are mounted in corners of the frame 2 , protrude upwards and are secured to it by means of bolts.
[0058] In an embodiment, the present disclosure includes folding stairs, especially lightweight wooden stairs, designed for installation in the ceiling of a building, opening downwards together with a flap designed for closing the opening in building ceiling from underside and unfolding into the room located under this ceiling, the folding stairs consisting of ladder-type stairs sections connected to each other by means of hinges located in individual joints of consecutive stairs segments at upper or lower ends of stringers of these stairs sections; wherein a first section which in unfolded state of stairs takes the highest position among all other sections is pivotally connected with the frame and its axis of rotation remains unchanged with respect to the frame, and the first section and the second section are connected with each other by means of high-axis hinges having their axis of rotation at an upper surface of the stringers of both these sections of stairs, characterized in that the flap ( 4 ) is suspended from the first section of stairs ( 11 ) by means of at least two pairs of connecting members ( 41 , 42 ) which, together with the first section of stairs and the flap form the four-bar linkage, and the connecting members ( 2 ) on which the flap is suspended are connected with the flap by means of hook-type holders ( 5 ), each of them having a bearing seat ( 52 ) for engaging the journal ( 44 ) seated in connecting member on which the flap is suspended, and the mounting access to this seat ( 51 ) is closed by the insert ( 55 ) having the surface ( 55 a ) complementing the seat and fastened to the hook-type holder ( 5 ) body by means of the latch.
[0059] The folding stairs may be characterized in that the bearing seat ( 52 ) of the hook-type holder ( 5 ) is open at both holder's sides forming a through opening, and the journal ( 44 ) of the connecting member ( 41 , 41 ) which suspends the flap end with the flange ( 45 ) having the diameter greater than the diameter of seat ( 51 ).
[0060] The folding stairs may be characterized in that the bearing surface ( 55 b ) of the insert ( 5 ) opposite with respect to the surface complementing the bearing ( 55 a ) rests, when the hook holder ( 5 ) is in closed state, on the supporting protrusion ( 56 ) in the body of hook-type holder.
[0061] The folding stairs may be characterized in that the insert ( 55 ) is movably connected with the body of hook-type holder ( 5 ) by means of the elastic connecting member ( 58 ) constituting a whole with the body of hook-type holder ( 5 ) and the insert ( 55 ).
[0062] The folding stairs may be characterized in that the catch ( 57 a ) of the latch ( 57 ) connected with the insert is located at the opposite side of the supporting protrusion ( 56 ) with respect to the insert ( 55 ), and the seat ( 56 b ) mating with the catch ( 57 a ) of the latch is located in supporting protrusion ( 56 ).
[0063] The folding stairs may be characterized in that the catch ( 57 a ) of the latch ( 57 ) is connected with the insert ( 55 ) by means of an elastic connecting member ( 57 b ) constituting a whole with the insert ( 55 ) and the catch ( 57 a ) of the latch. Stairs according to claim 1 , or claim 2 , or claim 3 , or claim 4 , or claim 5 , or claim 6 , characterized in that the first section ( 11 ) of stairs is connected with the frame ( 2 ) by means of hinged holders ( 3 ) secured to inner wall of the frame and in the pair of connecting members ( 41 ) on which the flap is suspended and located closest to the hinged holders, at least one member is made in the form of double-arm lever connected pivotally in its central area with the first section ( 11 ) of stairs and the arm of this double-arm lever which is opposite with respect to the flap is connected by means of the pull rod ( 47 ), with the frame ( 2 ), preferably with the hinged holder ( 3 ) fastened to this frame.
[0064] The folding stairs may be characterized in that the first section ( 11 ) of stairs is connected with the frame ( 2 ) by means of hinged holders ( 3 ) secured to inner wall of the frame and in the pair of connecting members ( 41 ) on which the flap is suspended and located closest to the hinged holders, at least one member is made in the form of double-arm lever connected pivotally in its central area with the first section ( 11 ) of stairs and the arm of this double-arm lever which is opposite with respect to the flap is connected by means of the pull rod ( 47 ), with the frame ( 2 ), preferably with the hinged holder ( 3 ) fastened to this frame.
[0065] The folding stairs may be characterized in that the first section ( 11 ) of stairs is suspended from the frame ( 2 ) also by means of a pair of spacer connecting members ( 6 ), and each of these members preferably consists of two flat pull rods ( 51 , 52 ) connected pivotally to each other by means of a pin ( 53 ).
[0066] The folding stairs may be characterized in that the spacer connecting members ( 6 ) are connected to transversal supporting beam ( 7 ), particularly situated near the half-length of the first section ( 11 ) of stairs and extending beyond the stringers ( 14 ) of this stairs section at both sides.
[0067] The folding stairs may be characterized in that they have tension springs ( 8 ) connecting the first section ( 11 ) of stairs with the frame ( 2 ), said springs assisting raising of stairs during their closing and attenuating dropping of stairs during their opening, and lower ends ( 5 ) of those springs are secured to movable components of stairs near the points where the supporting beam ( 7 ) connects with spacer connecting members ( 6 ). | The present disclosure provides a system of light weight folding stairs, especially lightweight wooden stairs, designed for installation in the ceiling of a building. For example, the light weight ladder-type stair system may be opened downwards and unfolded towards inside the room located under this ceiling. At least one ladder-type stair section is connected to a flap that fits within a frame in an opening in the ceiling, wherein the flap hinges open to access the folded stair sections. The ladder-type stair section is connected to the flap by a hook-type holder that allows installing the frame in a ceiling opening without the flap, which can be easily and quickly attached during final stage of assembly. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to an apparatus for kinetic energy storage.
[0003] 2. Description of the Prior Art
[0004] The prior art (DE 102010023531A1) discloses an apparatus for a smart network capacity control by kinetic energy storage.
[0005] The apparatus has a flywheel energy accumulator with an electric motor. The drawback of this apparatus consists in that the efficiency of this prior art apparatus for kinetic energy storage is relatively low because this apparatus operates under atmospheric pressure.
[0006] The prior at (DE 202011108033U) further discloses an apparatus with at least one energy recovery system for intermediate storage of a produced kinetic energy and which converts the kinetic energy into an electrical energy, wherein the at least one energy recovery system is formed of an electrical machine operable based on a reluctance principle and having a rotor formed as a flywheel body and a stator fixedly connected with the apparatus housing.
[0007] This prior art apparatus has actually a vacuumized chamber for minimizing the influence of air friction. In the vacuumized chamber, the flywheel accumulator is located. However, for producing vacuum, an external vacuum pump is provided. To this end, this apparatus requires, as is known from practice, a high vacuum pump and a vacuum pump to generate vacuum necessary in the housing with a flywheel accumulator. Also conceivable are arrangements having only one for vacuum pump, e.g., a two stage rotary vane pump.
[0008] The object of the invention is to provide a device for kinetic energy storage which would have a high efficiency with a minimized influence of the air friction in the apparatus, on one hand and, on the other hand, which can do without an upstream high vacuum pump or in which vacuum is improved without an additional high vacuum pump stage.
SUMMARY OF THE INVENTION
[0009] The inventive apparatus for kinetic energy storage has an electrical machine operable at least in one of motor mode and generator mode, and at least one energy recovery system for an intermediate storage of a produced kinetic energy and which converts the kinetic energy into an electrical energy, with the at least one energy recovery system having at least one flywheel body formed as a rotor, and a stator and with at least one of the rotor and the stator being formed as at least one vacuum pump stage.
[0010] The combination with a rapidly rotatable flywheel body with a suitable geometry enables a pumping action in the molecular region at a pressure ideal for the driving of the flywheel body, and leads to an increased reduction of gas friction.
[0011] The inventive apparatus can, e.g., be used in interruption-free current supply systems or also as kinetic energy accumulator for cars and in other fields of application. As an application field, wind energy installations or photovoltaic power systems can be envisaged in which the inventive apparatus can be used to bridge phases in which these installations or systems do not generate any current.
[0012] Because the energy recovery system itself is formed as a vacuum pump, the advantage of the inventive apparatus consists in that it is located in the housing, in which the flywheel body moves, with the flywheel body itself generating vacuum. There exists a possibility that the apparatus discharges against the atmospheric pressure. If necessary, a possibility exists, however, to use an inexpensive for vacuum pump. With this inventive construction, a vacuum is generated in the housing in which the flywheel body rotates, whereby the efficiency of the energy accumulator is increased. On the other hand, it is not necessary to provide an expensive high vacuum pump, e.g., a turbo molecular pump upstream of the apparatus. In the best case, additional or upstream pumps can be completely dispensed with. If necessary, the inventive apparatus can be arranged upstream of a booster pump for a turbo molecular pump.
[0013] According to a preferred embodiment, the rotor and the stator is formed as at least one of the Holweck-pump stage, Siegbahn pump stage, cross-channel pump stage, and screw-type pump stage.
[0014] The advantage of the so formed pump stages consist in that the flywheel accumulator can be so formed, together with the stator, that pump-active surfaces which are formed parallel to a rotational axis of the flywheel accumulator are formed as a screw-type pump stage or as cross-channel pump stage, and that pump-active surfaces which are formed transverse to the rotational axis are formed analogous to a Siegbahn pump stage. In addition at least one cross-channel pump stage can be provided. By combination of different pump stages, it is possible to actively use common pump-relevant surfaces in the apparatus together.
[0015] According to a further advantageous embodiment, the rotor is formed as a Holweck sleeve or as a Holweck cylinder. The pump-active channels can be provided in the rotor or in corresponding walls of the stator.
[0016] According to a still further advantageous embodiment of the invention, it is contemplated that the flywheel body or the housing has pump-active surfaces which are formed parallel to a rotational axis as a screw-type pump stage or as cross-channel pump stage, and pump-active surfaces which are formed transverse to the rotational axis, are formed as a Siegbahn pump stage. Thereby, the efficiency of the inventive apparatus is noticeably increased.
[0017] According to yet another advantageous embodiment of the invention, the flywheel body is formed as one of a rotatable sleeve and a rotatable cylinder. The sleeve or the cylinder is mounted on a hub. The advantage of this embodiment consists in that it is formed of simple and, therefore, inexpensively produced components.
[0018] A still another advantageous embodiment contemplates that the hub is formed as a hub a cross-section of which widens toward the flywheel body. In this embodiment, the mass of the flywheel body, which consist of the hub and a cylinder, noticeably increases, whereby the efficiency is likewise increases.
[0019] A still further embodiment of the invention contemplates that the flywheel body is formed as a rotatable solid cylinder secured directly on the rotor shaft. In this embodiment, the flywheel body has a very big mass, whereby the efficiency is noticeably increased.
[0020] A yet further embodiment of the invention contemplates that the flywheel body is formed of metal and/or fiber-unforced plastic material. When formed of metal, the flywheel body has a very big mass, whereby the energy accumulator is optimized. The advantage of forming the flywheel body of a carbon fiber-reinforced plastic material consists in that that flywheel body can be produced in a simple and cost-effective manner.
[0021] The inventive apparatus can have one or more outlets.
[0022] As bearings for the rotor shaft, roller bearings and/or active and/or passive magnetic bearings are provided.
[0023] The invention both as to its construction and its mode of operation, together with additional advantages and objects thereof, will be best understood from the following detailed description of preferred embodiments, when read with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The drawings show:
[0025] FIG. 1 a longitudinal cross-sectional view of an apparatus according the present invention;
[0026] FIG. 2 a longitudinal cross-sectional view of another embodiment of an apparatus according to the present invention;
[0027] FIG. 3 a longitudinal cross-sectional view of yet another embodiment of an apparatus according to the present invention;
[0028] FIG. 4 a plan view of a Siegbahn pump stage;
[0029] FIG. 5 a longitudinal cross-sectional view of still another embodiment of an apparatus according to the present invention;
[0030] FIG. 6 a longitudinal cross-sectional view of a further embodiment of an apparatus according to the present invention;
[0031] FIG. 7 a longitudinal cross-sectional view of a yet further embodiment of an apparatus according to the present invention; and
[0032] FIG. 8 a longitudinal cross-sectional view of a still further embodiment of an apparatus according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] FIG. 1 shows an apparatus 1 for kinetic energy storage and having a housing 2 , a rotor shaft 3 which is secured on a hub 4 . A flywheel body 5 , which is formed as a hollow cylinder, is also arranged on the hub 4 . Bearings 6 and 7 rotatably support the rotor shaft 3 . An electrical machine 8 that operates either as a motor or as a generator, has an electrical leadthrough 9 leading to an electrical connection 10 .
[0034] The flywheel body 5 has channels 1 la which, together with inner wall 12 a of the housing 2 , form a screw-type pump stage 16 . The screw-type pump stage 16 cooperates with inner walls 12 a.
[0035] The view in FIG. 1 shows simply an exemplary embodiment. With a Holweck pump stage, pump-active surfaces are arranged in the housing, and the rotor surfaces are formed smooth. With the screw-type pump stage 16 , the pump-active surfaces are provided in the rotor surface, and the inner surfaces of the housing are formed smooth. Usually, with a Siegbahn pump stage, pump-active surfaces are provided in the housing, and the rotor is formed smooth. However, the following figures show that in Siegbahn pump stage a design is selected in which pump-active surfaces are provided in the rotor, and the inner wall of the housing is formed smooth. The channels 11 b cooperate with an inner wall 12 b and form a screw-type pump stage.
[0036] Siegbahn pump stages 13 a , 13 b cooperate with inner walls 14 a , 14 b . Naturally, another embodiment, not shown, is possible in which the stator surfaces 14 a , 14 b have grooves corresponding to Siegbahn pump stage and cooperate with corresponding surfaces 13 a , 13 b of the rotor which are formed smooth.
[0037] In addition, further Siegbahn pump stages 15 a , 15 b are provided on the hub 4 . When the rotor shaft 3 is rotated, together with the hub 4 and the flywheel body 5 , the screw-type pump stages 11 a , 12 a, 11 b 12 b evacuate a hollow space 17 of the housing 2 through the outlet 18 . The direction of gas molecules, which are transported by the pump stages, is shown with arrow A. Therefore, the flywheel body 5 can rotate in the evacuated hollow space 17 free from air friction. The rotor 25 of the apparatus 1 is formed of the rotor shaft 3 , the hub 4 , and the flywheel body 5 .
[0038] The gas molecules are transported by the Siegbahn pump stages 15 a radially outwardly relative to the rotor shaft 3 . Further transportation is carried out by the screw-type pump stage that cooperates with the inner wall 12 b . Finally, the gas molecules are transported by the Siegbahn pump stage 13 a to the channels 1 la of the further screw-type pump stage. Further transportation of the gas molecules is carried out from the Siegbahn pump stage 13 b in direction of the screw-type pump stage 11 b and from there further in direction of the Siegbahn pump stage 15 b before the gas molecules are transported to the outlet 18 .
[0039] FIG. 2 shows an embodiment of the apparatus 1 that substantially corresponds to the construction of the apparatus 1 according to FIG. 1 . The components common with those of FIG. 1 are designated with the same reference numerals and are not further described. Only substantial changes are described.
[0040] According to FIG. 2 , an additional screw-type pump stage 19 , which increases the pumping capacity of the apparatus 1 is arranged on the rotor shaft 3 . At this location, also, a Holweck pump stage with channels provided in the stator or a cross-channel pump stage with opposite channels in the stator and rotor can be arranged.
[0041] FIG. 3 shows an embodiment of an apparatus 1 in which common components are not described, only substantial changes are.
[0042] According to FIG. 3 , a further pump stage which is formed as a cross-channel pump stage, is arranged on the rotor shaft 3 . In the cross-channel pump stage 20 pump-active surfaces are provided on the rotor and the inner wall of the housing. The pump-active surfaces on the housing inner wall are not shown for better clarity.
[0043] In the apparatus 1 according to FIG. 3 , the electrical machine 8 is located outside of the housing 2 in a separate housing component 21 . The rotor shaft 3 is driven through a mechanical leadthrough 22 that advantageously has a seal. Thus, the electrical machine 8 is located outside of the housing 2 .
[0044] The inlet 18 , in distinction from the embodiments of FIGS. 1 and 2 , is located in the vicinity of the rotor shaft.
[0045] FIG. 4 shows a Siegbahn pump stage 13 . The Siegbahn pump stages 13 , 15 according to FIGS. 1 through 3 are formed with pump-active surfaces which extend transverse to the rational axis of the rotor.
[0046] FIG. 5 shows an apparatus 1 with the housing 2 , rotor shaft 3 , bearings 6 and 7 , and an electrical machine 8 .
[0047] The electrical leadthrough 9 to the electrical connection 10 and the outlet 18 are analogous to those in the embodiment of FIG. 1 .
[0048] The flywheel body 5 is secured directly on the rotor shaft 3 . The flywheel body 5 has, in addition, a cross-section that expands from the rotor shaft 3 radially outwardly. In the gap between the rotor and the stator which extends from the rotor shaft 3 to the Siegbahn pump stage 13 a , further pump stages can be integrated by providing grooves in the rotor and/or in the corresponding stator surfaces. The flywheel body 5 is again is provided with channels 11 which form, together with the inner wall 12 of the housing 2 , a screw-type pump stage. In addition, there are provided Siegbahn pump stages 13 a , 13 b . Additionally, a screw-type pump stage 19 is arranged on the rotor shaft 3 . The advantage of this embodiment consists in that the flywheel body has a very large mass.
[0049] FIG. 6 shows an embodiment of an apparatus 1 . The components common with those of FIGS. 1 , 2 , 3 and 5 are not described in detail, only essential changes are.
[0050] According to FIG. 6 , the apparatus has, in addition to the outlet 18 , a further outlet 23 . The gas feeding direction starts at the middle of the screw-type pump stage/Holweck pump stage 16 , with the gas being partially transported to the Siegbahn pump stage 13 a and partially to the Siegbahn pump stage 13 and, finally, in direction of the outlets 18 , 23 .
[0051] FIG. 7 shows a further apparatus 1 with a housing 2 . A hollow space 17 is provided in the housing 2 . The apparatus 1 includes a rotor shaft 3 which is supported in bearings 6 , 7 .
[0052] In addition, there is provided an electrical machine 8 with an electrical leadthrough 9 to an electrical connection 10 . The flywheel body 5 is formed as a hollow cylinder. The hollow cylinder has a very big mass. The hollow cylinder has, on its outer side, channels 11 which form a screw-type pump stage.
[0053] Through the outlet 18 , the flywheel body 5 aspirated vacuum into the hollow space 17 .
[0054] The outlet 18 can be provided at another location. It is also possible to arrange the electrical machine 8 and the bearing 7 outside the housing 2 . In addition, Siegbahn pump stages 13 a , 13 b are provided on the flywheel body 5 .
[0055] FIG. 8 shows yet another embodiment of an apparatus 1 having a housing 2 , a rotor shaft 3 rotatably supported in the housing 2 and on which a hub 4 is provided.
[0056] The rotor shaft 3 is supported in a magnetic bearing 24 and a ball bearing 7 . In addition, there are provided an electrical machine 8 and an outlet 18 . In the apparatus 1 , there is provided a rotor 25 that is formed of the rotor shaft 3 , hub 4 , and sleeve 5 .
[0057] The bearing arrangement formed of the magnetic bearing 24 and the ball bearing 7 has an advantage that consists in that that lubricant-free bearing is provided in the hollow space 17 . On the shaft 3 , there is provided a permanent magnet 26 that cooperates with an energized drive spool 27 . Thereby, the rotor 25 can be rotated with a sufficiently high speed. A stator 28 has on its outer surface adjacent to the rotor one or a plurality of helical channels 11 . This embodiment is so formed that the stator 28 carries the channels rather than the flywheel body 5 . Thus, a Holweck pump stage is formed.
[0058] Though the present invention was shown and described with references to the preferred embodiments those are merely illustrative of the present invention and are not to be construed as a limitation thereof and various modifications of the present invention will be apparent to those skilled in the art. It is therefore not intended that the present invention be limited to the disclosed embodiments or details thereof, and the present invention includes all variations and/or alternative embodiments within the spirit and scope of the present invention as defined by the appended claims. | An apparatus for kinetic energy storage includes an electrical machine operable at least in one of motor mode and generator mode, and at least one energy recovery system for an intermediate storage of a produced kinetic energy and which converts the kinetic energy into an electrical energy, with, the at least one energy recovery system having at least one flywheel body formed as a rotor, and a stator and with at least one of the rotor and the stator being formed as at least one vacuum pump stage. | 5 |
FIELD OF THE INVENTION
The present invention relates generally to a composition for the treatment of malignant tumors and, more specifically, to its use in a method for the treatment of carcinomas and sarcomas.
BACKGROUND OF THE INVENTION
Breast cancer is a malignant abnormal cell growth in the breast. Cancer cells may spread to other areas of the body (called metastasis). Fibrocystic changes (e.g., formation of cysts, scar tissue) may cause benign (i.e., noncancerous) lumps in the breast.
In women, breast cancer is the second most common type of cancer and the second leading cause of cancer-related deaths. One in eight women in the United States will develop breast cancer during their lifetimes.
Approximately 200,000 women in the United States are diagnosed with breast cancer each year, and the disease causes about 40,000 deaths annually.
The incidence of breast cancer rises after age 40. The highest incidence (approximately 80% of invasive cases) occurs in women over age 50.
Most breast cancer develops in glandular tissue and is classified as adenocarcinoma. The earliest form of the disease, ductal carcinoma in situ (DCIS), develops solely in the milk ducts. The most common type of breast cancer, invasive ductal carcinoma (IDC), develops from DCIS, spreads through the duct walls, and invades the breast tissue.
Invasive lobular carcinoma originates in the milk glands and accounts for 10-15% of invasive breast cancers. Less common types of breast cancer include the following:
Inflammatory (breast tissue is warm and appears red, and tends to spread quickly); Medullary carcinoma (originates in central breast tissue); Mucinous carcinoma (invasive; usually occurs in postmenopausal women); Paget's disease of the nipple (originates in the milk ducts and spreads to the skin of the nipples or areola); Phyllodes tumor (tumor with a leaf-like appearance that extends into the ducts; rarely metastasizes; and Tabular carcinoma (small tumor that is often undetectable by palpation).
While sarcomas (cancer of the connective tissue) and lymphomas (cancer of the lymph tissue) develop in the breasts, they are relatively rare occurrences.
Approximately 5% of breast cancer cases have a genetic link that results from an inherited mutation in genes identified as BRCA1 and BRCA2. Patients who inherit an altered BRCA1 or BRCA2 gene have an increased risk for developing premenopausal breast cancer and are more likely to have family members with the condition.
The cause of breast cancer is unknown.
The diagnosis of breast cancer is made through a process called triple assessment, which includes:
1. clinical examination; 2. imaging procedures e.g., mammogram, breast ultrasound, magnetic resonance imaging (MRI scan); and 3. biopsy (surgical removal of tissue for microscopic examination) of a mass detected by physical examination or mammogram.
There are various options for the treatment of breast cancer. They include surgery, radiation, immunotherapy, hormonal, chemotherapy, and radiation or one or more of the foregoing options in combination.
Surgery combined with radiation and/or chemotherapy is the most common treatment for breast cancer. The type of surgical procedure recommended to the patient depends on the stage of the disease. Mastectomy is the most commonly performed procedure.
Radiation uses high-energy x-rays to destroy cancer cells. Treatment is delivered by a machine outside the body (called external radiation) or by radioactive “seeds” that are placed directly into the tumor (called brachytherapy). Breast cancer is usually treated using external radiation.
Radiation may be used to shrink the tumor before surgery (called neoadjuvant therapy) or may be used after surgery to destroy cancer cells that remain in the breast, chest wall, or underarm (called adjuvant therapy).
Radiation therapy is performed in a hospital or an outpatient center. Each treatment lasts a few minutes and treatment is usually given 5 days per week, for 6 weeks. Side effects include fatigue, reddening of the skin and swelling.
Several drugs have been developed to treat breast cancer that is responsive to estrogen. Selective estrogen-receptor modulators (SERMs; e.g., tamoxifen, raloxifene) inhibit the effects of estrogen on breast cancer cells.
Tamoxifen (Nolvodex®) is taken in pill form, usually for 5 years after breast cancer surgery to prevent recurrence. After 5 years, patients taking tamoxifen have an increased risk for early stage cancer of the lining of the uterus. The most common side effect of this medication is hot flashes. Other side effects include the following: depression, dizziness, hair loss, headache, and swelling. Studies are being conducted to determine if raloxifene (Evista®) can effectively reduce the risk for breast cancer. Side effects include hot flashes and leg cramps.
Fulvestrant (Faslodex®) destroys estrogen receptors in breast cancer cells. It is used to treat metastatic breast cancer in postmenopausal women who have been treated unsuccessfully with tamoxifen. This treatment is administered once a month by intramuscular injection. Side effects include nausea, hot flashes, and weight gain.
Goserelin (Zolodex®) is a synthetic form of luteinizing hormone-releasing hormone (LHRH) that is prescribed to treat metastatic breast cancer in premenopausal women. This medication signals the body to stop producing estrogen, depriving the tumor of the estrogen it needs to grow. Several weeks are needed before tumor growth slows. Side effects include hot flashes, sexual dysfunction, increased pain, and rash.
Aromatase inhibitors (e.g., anastozole [Arimidex®], letrozole [Femara®], exemestane [Aromasin®] inhibit the action of the enzyme aromatase, which is involved in estrogen production in postmenopausal women. These drugs may be prescribed for postmenopausal women with advanced breast cancer that has been unsuccessfully treated with tamoxifen. Side effects include the following: cough, depression, diarrhea, dizziness, fatigue, headache, hot flashes, increased appetite, nausea and pain.
Chemotherapy is a systemic treatment i.e., travels throughout the body via the bloodstream, that often uses a combination of drugs to slow tumor growth and destroy cancer cells. Drugs may be administered orally or intravenously. Chemotherapy is often used as an adjuvant therapy to destroy breast cancer cells that have metastasized to the lymph nodes. It also is used to shrink the tumor prior to surgery (neoadjuvant therapy) and as a primary treatment.
The combination most commonly prescribed to treat breast cancer is doxorubicin (Doxil®) and cyclophosphamide (Cytoxin®). Paclitaxel (Taxol®, or the generic form, Paxene®) is often prescribed after this combination treatment, when breast cancer has metastasized to the lymph nodes. It is also prescribed following breast cancer surgery. Other chemotherapy drugs include docetaxel (Taxotere®) and gemcitabine (Gemzar®).
Side effects are often severe and include fatigue, hair loss (alopecia), fever, low blood cell count (e.g., anemia, neutropenia, thrombocytopenia), infection and nausea.
Biological therapy (also called immunotherapy) involves using trastuzumab (Herceptin®) to inhibit tumor growth and enhance the immune system's ability to fight cancer. It also may be combined with chemotherapy as a first line treatment for metastatic breast cancer and may be used after chemotherapy or anti-estrogen therapy to improve the effectiveness of the treatment. When used alone or in combination, side effects include cardiac dysfunction (causes severe cough, shortness of breath, difficulty performing physical activities), chills, congestive heart failure, cough, diarrhea, fever, headache, nausea, weakness and vomiting.
Despite the positive results obtained in clinical applications in chemotherapy, the search for new compounds and compositions is still open to the identification of new compounds with optimal features of reduced toxicity and increased tumor selectivity.
SUMMARY OF THE INVENTION
The present invention is a chemical composition and a method for administration for the treatment of malignant tumors in mammals, including carcinomas, sarcomas, and lymphomas. The composition of the present invention, has been found to be particularly effective with respect to the treatment of carcinomas of the breast and lymphomas.
It is an object of the present invention to provide a chemotherapeutic composition and method for treating mammalian cancers of the breast, the lymphatic system, such as Hodgkins and non-Hodgkins lymphoma, Burkitts lymphoma, and Ehrlich's ascites tumor.
DETAILED DESCRIPTION OF THE INVENTION
It has been found that a composition comprising a mixture of ammoniated mercury, zinc oxide and citric acid when administered to a mammal suffering from a variety of cancers provides an effective method for treating such mammalian cancers.
The quantity of ammoniated mercury in the composition of the present invention can be from about 0.1 grams to about 10 grams, with the preferred quantity being 0.2 grams. The amount of zinc oxide in the composition can be from about 0.1 grams to about 50 grams, with 0.1 grams being preferred. The quantity of citric acid present in the medicinal composition of the present invention can be from about 0.1 grams to about 100 grams, with 50 grams being the preferred quantity.
The composition of the present invention is prepared, in a preferred embodiment, by adding 50 gm of citric acid to 100 ml of distilled water and heating until a temperature of 80° C. is reached. Then 0.2 gm of ammoniated mercury is added to the citric acid solution and mixed well until the ammoniated mercury is dissolved. Then 0.1 gm of zinc oxide is added with mixing until dissolution occurs. The solution containing the three (3) ingredients is then added to 900 ml of distilled water and heated to 90° C., with stirring for five (5) minutes. The solution is then allowed to cool for three hours.
The composition of the present invention can be used effectively in various forms, such as tablets, capsules, suppositories or solutions. The various forms can be prepared by known methods using conventional solid carriers, such as, for example, lactose, starch and talcum, or by using liquid carriers, such as, for example, water, fatty oils, essential oils, liquid paraffins and alcohol.
Other carriers which may be employed to advantage include animal and vegetable proteins, such as gelatins, dextrins and soy; gums such as acacia, guar, agar and xanthan; polysaccharides, alginates; carboxymethylcelluloses; carragenans, dextrans, pectins; synthetic polymers, such as polyvinylperrolidone; sugars such as mannitol, dextrose, galactose, and trehalose; inorganic salts, such as sodium phosphate, sodium chloride, and aluminum silicates, and amino acids having from 2 to 12 carbon atoms such as glycine, L-alanine, L-aspartic acid, L-glutamic acid, L-hydroxyproline, L-isoleucine, L-lucine, and L-phenylalanine.
Auxiliary components which can optionally be added during compounding include tablet disintegrants, solubilizers, preservatives, anti-oxidants, surfactants, viscosity enhancers, coloring agents, flavoring agents, pH modifiers, sweeteners and taste-making agents among others. Exemplary coloring agents, which can be used, include red, black and yellow iron oxides and FD&C dyes, including FD&C Blue No. 2 and Red No. 40. Examples of the flavoring agents which can be used to advantage are mint, raspberry, licorice, orange, lemon, grapefruit, caramel, grape and combinations thereof. Suitable pH modifiers include citric acid, tartaric acid, phosphoric acid, hydrochloric acid, and maleic acid. Suitable sweeteners include aspartame, acesulfane K and thaumatin. Taste-masking agents which can be used include sodium bicarbonate, ion-exchange resins, cyclodextrin inclusion compounds, adsorbates, and microencapsulated actives.
The composition of the present invention can be administered in a variety of modes. For example, the administration may be oral, parenteral, including subcutaneous, e.g., by injection or by depot tablet, intradermal, intrathecal, intramuscular, e.g., by depot, intravenously, rectal, or topical, including dermalbuccal and sublingual. Formulations for oral administration may be presented as discrete units, such as capsules, cachets, or tablets, each containing a predetermined amount of the active ingredients; as a powder or granules, as a solution or in suspension in an aqueous liquid or a non-aqueous liquid; or as an oil-in-water liquid.
Formulations for parenteral administration include aqueous and non-aqueous sterile injection solutions, which may contain anti-oxidants, buffers, bacteriostats and solvents which render the composition isotonic with the blood of the intended recipient, as well as aqueous and non-aqueous sterile suspensions which may include suspending agents and thickening agents.
Oral administration in the form of a liquid solution is the preferred method for the administration of the composition of the present invention. The dosage level is dependent upon a number of factors, including the weight and physical condition of the patient, the particular condition which is being treated, and the amount of the active ingredients present in the administered dose. For example, a suitable dose for an 160 lb. adult male is from about 1 to about 5 mls., either 3 or 4 times daily.
The composition of the present invention has been found to result in the normalization of certain physiological parameters, namely, organ weight and level of erythrocytes and leucocytes, extension of the latent period and reduction of tumor weights.
EXAMPLE 1
The antitumor activity of the medication of the present invention was studied in mice and rats with transplantable tumors of Sarcoma 37, 45, and 180, and Ehrlich ascites tumor.
Necrosis-free pieces of tumoral tissue (a peripheral part of a tumoral node) cut with scissors to form a homogeneous mass served as transplantants for solid models (Sarcomas 37, 45 and 180). A sterile physiological solution in the proportion of 1:3-1:4 was added to the tumor and the resulting suspension was introduced with a syringe subcutaneously to the animals. The transplantation was conducted in sterile box conditions using 12-14 days' tumor as a donor. The transplantation of sarcomas 37 and 180 was performed by means of subcutaneous introduction of 0.2-0.3 ml of the 20% tumoral suspension in a physiological solution to the axillary crease of each mouse. For the transplantation of Sarcoma 45, by 0.4-0.5 ml of suspension of tumoral cells was introduced subcutaneously (to the lateral area) of each rat. On the 4 th -5 th days after inoculation, when the transplanted tumor is usually pea-size, the animals were divided into test and control groups each having 8 mice and 10 rats. Within 6-8 days, the medicated composition of the present invention was introduced to the animals in the test groups through a gastric tube. A day after the last injection of the medication, the animals were killed with ether, weighed, and the weight of tumors was measured separately. The therapeutic effect was estimated by the percent of tumor growth suppression (TGS) compared to the control group.
As a reference medication for comparative assessment of the therapeutic action of the present invention under analogous experimental conditions, 5-fluorouracil was used, an antimetabolite largely applied in oncological practice, considering that by the mechanism of antitumoral action phytogenic medications are more similar to antimetabolites than to alkylating agents.
In the case of Ehrlich ascites tumor, the tumor was transplanted to mice intraperitoneally. Under sterile conditions, the ascitic fluid was taken from animals with 8-10 days' ascetic tumor and introduced into the abdominal cavity of healthy mice by 0.2 ml. Twenty-four (24) hours after the transplantation, the animals were divided into groups and start to receive the medication once a day within 6 days. After introduction of the medication ceased, the animals were killed and weighed. The ascetic fluid was extracted from the abdominal cavity. Then the mice were weighed again to estimate the volume of ascetic fluid. The therapeutic effectiveness was estimated on the basis of the obtained weight data.
In the study of antitimor properties of the medication of the present invention, the medication was used in doses of 20 and 40 ml/kg, and 10 and 30 ml/kg in the tests on mice and rats, respectively. The general toxic action which the medication had on the organism of the tested animals was estimated by their outer appearance and behavior during the experiment, as well as by the Growth Ratio (G R ) expressed in percent.
The numerical data obtained was processed statistically by Student-Fisher's method. The data were considered reliable in case of P<0.05.
The results of the chemotherapeutic experiments summarized in the table below attest that the medication or composition of the present invention displays notable antitumor activity with respect to the Ehrlich ascites tumor. In doses of 20 and 40 ml/kg, the medication causes inhibition of ascit accumulation by 52% (P<0.05) and 56% (P<0.05), respectively. Under analogous experimental conditions, the antitumor effect of 5-fluorouracil reference medication used in the optimal therapeutic dose of 25 ml/kg comprised 70% (P<0.05). The data presented in Table 1 leads to the conclusion that the preparation is less effective with respect to the sarcoma models.
The medication caused a slight inhibition of the growth of the mentioned tumors only when applied in relatively high concentrations (30 ml/kg for rats and 40 ml/kg for mice). The therapeutic action of the preparation in the tests with Sarcomas 45, 37 and 180 comprised, respectively, 32, 36 and 34% (P=0.05). In lower concentrations, the antitumor activity of the medication for the listed models did not exceed 24% (P>0.05).
Under identical experimental conditions, 5-fluorouracil synthetic antitumoral medication inhibited the growth of Sarcomas 45 and 180 by 32% (P=0.05) and 45% (P<0.05), respectively. Its therapeutic effect equaled 70% only in the tests with Sarcoma 37 (P<0.05).
It is important to note that systematic observation of animals along with the course of introduction of the composition of the present invention in all chemotherapeutic experiments did not reveal any changes of their general condition, or behavior. In all cases, the animals' growth rate indicators for the medication had positive values and varied from 5.4 to 8.0% (Table 1), which indicates a large increase in weight, or a lower weight loss of the treated animals in the course of the experiment, and provides indirect evidence of lack of toxic action of the medication on the animals' organism. Under similar experimental conditions, the G R for 5-fluorouracil had negative values (from −7.3 to −11) in all tests, which indicates clear toxic action of the medication on the organism of the test animals.
TABLE 1
Tumors
Dose (ml/kg)
TGS, %
G R %
Ehrlich Ascites
20
52 (P < 0.05)
7.6
Tumor
40
56 (P < 0.05)
6.3
Sarcoma 180
20
21 (<0.05)
6.4
40
34 (P = 0.05)
6.1
Sarcoma 37
20
24 (P > 0.05)
5.4
40
36 (P = 0.05)
6.7
Sarcoma 45
10
22 (P > 0.05)
8.0
30
32 (P = 0.05)
7.6
Therefore, the data show that the invention displays an antitumor activity with respect to some of transplantable animal tumors.
The antitumor activity of the composition of the present invention attests that this medication has a therapeutic action with respect to the Ehrlich ascites tumor. High concentrations of the composition cause inhibition of growth of the sarcomas without having any toxic action on the organism of tested animals.
While the illustrative embodiments of the invention have been described with particularity, it will be understood that numerous modifications will be apparent to, and can readily be made, by those of ordinary skill in the art. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the example and descriptions set forth herein, but rather, that the claims be construed as encompassing all the features of patentable novelty which reside in the present invention, including all features which would be treated as equivalents thereof by those of ordinary skill in the art to which this invention pertains. | A composition and method for treating mammals suffering from malignant tumors which involves administering a composition including ammoniated mercury, zinc oxide and citric acid. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims foreign priority benefits under 35 U.S.C. §119(a)-(d) to GB 1512666.7 filed Jul. 20, 2015, which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] This invention relates to a motor vehicle having an instrument panel.
BACKGROUND
[0003] It is well known to provide a motor vehicle with an instrument panel (often alternatively referred to as a dashboard) mounted in a passenger compartment of the motor vehicle and extending across the width of the passenger compartment of the motor vehicle.
[0004] Various instruments are mounted in the instrument panel and it also often houses ducting for part of a ventilation system of the motor vehicle and in some cases one or more airbags
SUMMARY
[0005] FIG. 1 is a schematic side view of a prior art motor vehicle 1 showing a conventionally mounted instrument panel 10 in a passenger compartment 6 of the motor vehicle 1 . The motor vehicle 1 comprises a roof 2 , a floor 3 , a windscreen 4 and a firewall or bulkhead 5 separating the passenger compartment 6 from a front compartment 7 . In a motor vehicle having a front mounted engine the engine is mounted in the front compartment 7 and in a motor vehicle having a rear mounted engine the front compartment 7 forms a luggage storage area.
[0006] A windscreen frame (not shown) for housing the windscreen 4 is joined at a bottom end to other structural components of the motor vehicle 1 including the bulkhead 5 .
[0007] The instrument panel 10 is mounted on the bulkhead 5 or is mounted on a cross-vehicle beam (not shown), in either case, the instrument panel 10 abuts against a bottom end of the windscreen 4 .
[0008] In the event of a severe frontal collision a front end of the motor vehicle 1 is designed to crush so as to absorb energy as is well known in the art.
[0009] For small vehicles and, particularly, small rear-engined vehicles, maximum utilization of the available crush space is critical in order to deliver good crash performance. Where the available crush length is small such as A-class and City vehicles there may be some level of intrusion to the structure supporting the bottom of the windscreen if the frontal impact is severe. That is to say, a bottom end of the windscreen is located within a front crush zone of the motor vehicle. Such intrusion can result in parts of the instrument panel becoming detached or breaking and thereby constituting a risk to an occupant of the motor vehicle.
[0010] It is an object of the invention to reduce the risk of instrument panel damage in the event of a frontal collision.
[0011] According to the invention there is provided a motor vehicle having a body structure defining a passenger compartment, an elongate instrument panel mounted in the passenger compartment, a windscreen having a bottom end attached to the body structure of the motor vehicle wherein the instrument panel is spaced away from the bottom end of the windscreen so as to define a gap therebetween and a cover is provided to cover the gap between the bottom end of the windscreen and an upper surface of the instrument panel.
[0012] The body structure may include a bulkhead separating the passenger compartment from a front compartment of the motor vehicle and the instrument panel may be spaced away from the bulkhead.
[0013] The instrument panel may only be connected at each end to the body structure of the vehicle.
[0014] The instrument panel may include a mounting beam that is used to support the instrument panel and connect the instrument panel at each end to the body structure of the vehicle.
[0015] The cover may have a first end connected to the body structure of the motor vehicle adjacent to the bottom end of the windscreen and a second end that is positioned during normal use upon the upper surface of the instrument panel.
[0016] If the longitudinal dimension of the gap between the bottom end of the windscreen and the instrument panel reduces, the second end of the cover may be arranged to slide over the upper surface of the instrument panel.
[0017] The bottom end of the windscreen may be located in a front crush zone of the motor vehicle and the gap may position the instrument panel away from the bottom end of the windscreen out of the front crush zone of the motor vehicle.
[0018] The motor vehicle may be a rear-engined motor vehicle.
[0019] The invention will now be described by way of example with reference to the accompanying drawing of which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a schematic side view of a prior art motor vehicle showing a conventionally mounted instrument panel in a passenger compartment of the motor vehicle;
[0021] FIG. 2 is a schematic side view similar to FIG. 1 but showing how an instrument panel is mounted in a passenger compartment of a motor vehicle constructed in accordance with the invention;
[0022] FIG. 3 is a schematic view in the direction of arrow X on FIG. 2 ;
[0023] FIG. 4 is side view similar to FIG. 2 but showing in more detail the positioning of the instrument panel and a cover used to bridge a gap between the instrument panel and a bottom end of a windscreen of the motor vehicle; and
[0024] FIG. 5 is an enlarged cross section in the region “R” on FIG. 4 showing a living hinge forming part of the cover.
DETAILED DESCRIPTION
[0025] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
[0026] With reference to FIGS. 2 to 5 there is shown a small rear-engined motor vehicle 101 having a roof 102 , a floor 103 , a windscreen 104 and a firewall or bulkhead 105 separating a passenger compartment 106 from a front compartment 107 . In this case, because the motor vehicle 101 has a rear mounted engine (not shown), the front compartment 107 forms a luggage storage area for the motor vehicle 101 .
[0027] A distance “D” from a front end of the motor vehicle 101 to a bottom end of the windscreen 104 is small so that a corresponding crush distance (CD 1 on FIG. 4 ) is small.
[0028] A windscreen frame for housing the windscreen 104 is structurally joined at a bottom end to other structural components of the motor vehicle 101 forming part of a body structure of the motor vehicle 101 such as the bulkhead 105 .
[0029] An instrument panel 110 is mounted on a laterally-extending cross-vehicle beam 115 that is connected at opposite lateral ends to part of the body structure of the motor vehicle 101 .
[0030] The instrument panel 110 is connected at each end to the body structure of the vehicle via the mounting beam 115 which both supports the instrument panel 110 and connects it at each end to the body structure of the vehicle 101 . The instrument panel 110 extends across the entire width of the passenger compartment 106 . The instrument panel 110 is spaced away from the bulkhead 105 and there are no structural connections between the bulkhead 105 and the instrument panel 110 .
[0031] The windscreen 104 of the motor vehicle 101 has a bottom end attached via a bonding strip 109 to the body structure of the motor vehicle 101 . The instrument panel 110 is spaced away from the bottom end of the windscreen 104 so as to define a gap “G” therebetween and a cover 120 made from a plastic material is provided to cover the gap “G” between the bottom end of the windscreen 104 and an upper surface 110 u of the instrument panel 110 .
[0032] As best seen in FIGS. 4 and 5 the cover 120 has a first/rear end 121 that rests upon the upper surface 110 u of the instrument panel 110 or, to be more precise, upon trim forming the upper surface of the instrument panel 110 and has a second/front end 122 connected to a fastening member which in this case is in the form of an elongate fastening strip 123 used to connect the cover 120 to part of the body structure of the motor vehicle 101 . It will be appreciated that prior to impact the cover 120 may be attached to the instrument panel 110 in a frangible manner to prevent rattling. The attachment of the cover 120 to the instrument panel 110 is easily broken when a load is applied to it so as not to prevent sliding of the cover 120 .
[0033] A living hinge 124 provides a rotatable connection between the second/front end 122 of the cover and the fastening strip 123 .
[0034] It will be appreciated that the cover 120 , the fastening strip 123 and the living hinge 124 are all formed as integral parts of a single component made from a plastic material.
[0035] In FIG. 4 when the cover is in a pre-impact position it is indicated by the reference number 120 when the cover is in a post impact position it is shown in dotted outline referenced 120 ′. Note that only the cover 120 ′ is shown in the post impact position and not the support structure for the cover 120 ′.
[0036] The post impact position corresponds to a situation where the bottom end of the windscreen 104 has moved back and the gap “G” between the bottom end of the windscreen 104 and the instrument panel 110 has been absorbed by the impact. It will be appreciated that the instrument panel 110 has not moved it is the relative movement between the bottom end of windscreen 104 and the instrument panel 110 that results in a diminishing in the longitudinal dimension of the gap “G”.
[0037] Because the cover 120 rides up onto and slides across the upper surface 110 u of the instrument panel 110 no significant force is transferred to the instrument panel 110 until all the gap “G” is absorbed. The longitudinal dimension of the gap “G” is therefore set to be as large as possible taking into account packaging constraints for the instrument panel 110 such as the distance required between the instrument panel 110 and any occupants of the motor vehicle 101 . The longitudinal dimension of the gap “G” is set so as to move the instrument panel 110 out of a front crush zone CZ of the motor vehicle 101 .
[0038] The longitudinal dimension of the gap “G” is typically, by way of example and without limitation, in the range of 0.020 to 0.120 m as such a gap provides a good compromise between packaging and improved crash properties.
[0039] In FIG. 4 the difference in available crush distance between a motor vehicle having an instrument panel mounted adjacent to a bottom edge of a windscreen and a motor vehicle constructed in accordance with this invention having the instrument panel mounted so that a gap is present is shown.
[0040] In the case of a prior art motor vehicle the available crush distance is shown as CD 1 . When the crush distance CD 1 is used up due to collapse of the front of the vehicle resulting from a frontal impact, a considerable force will be transferred from the body structure of the motor vehicle into the instrument panel because it abuts the lower edge of the windscreen 104 .
[0041] In the case of a motor vehicle constructed in accordance with this invention, an available crush distance CD 2 is provided. Therefore, it is not until the increased crush distance CD 2 is used up will any force be transferred from the body structure of the motor vehicle 101 into the instrument panel 110 . The difference in crush distance ACD between CD 2 and CD 1 corresponds to the longitudinal dimension of the gap “G” between the bottom end of the windscreen 104 and the instrument panel 110 as shown in FIG. 2 . The corresponding crush zone CZ for the motor vehicle 101 for a predefined serious crash condition will be greater than CD 1 but less than CD 2 as indicated by the double headed arrow CZ on FIG. 4 .
[0042] The function of the cover 120 is to cover the gap “G” between the bottom end of the windscreen 104 and the instrument panel 110 so as to provide an aesthetically pleasing appearance and to prevent objects placed upon the upper surface 110 u from falling down behind the instrument panel 110 .
[0043] Although the invention has been described with reference to an instrument panel that is supported by a structural beam it will be appreciated that other types of construction could be used for the instrument panel so as to provide it with sufficient rigidity and strength to be supported only at each end. For example and without limitation, the instrument panel can include a skeletal body that is used to support the instrument panel and connect the instrument panel at each end to the body structure of the vehicle. For example, the instrument panel could have a die cast core and an overlying fascia member. See for example the instrument panel construction disclosed in Patent Publication WO2005/021362.
[0044] Furthermore the invention is not limited to the use of a living hinge other types of connection allowing the cover to rotate relative to the body structure so as to allow it to ride up onto and slide across the upper surface of the instrument panel could be used such as, for example, one or more conventional mechanical hinges. Alternatively, the cover could have a first end attached to the body structure near the bottom end of the windscreen and a second end resting upon the upper surface of the dashboard during normal use and be made from a resilient flexible material enabling it to flex or bend sufficiently near its first longitudinal edge to permit the second edge to slide over the upper surface of the instrument panel when the gap is reduced due to a frontal impact.
[0045] As yet another alternative the cover could have a first end attached to the body structure near the bottom end of the windscreen, a second end attached to the instrument panel and have a number of corrugations running substantially parallel to the lower end of the windscreen. The corrugations facilitate the easy collapse of the cover between the first and second ends when the longitudinal dimension of the gap between the bottom end of the windscreen and the instrument panel reduces.
[0046] The connection means used to attach the cover to the body structure in all cases is such that it tethers the cover to the body structure during a frontal impact.
[0047] It will be appreciated by those skilled in the art that although the invention has been described by way of example with reference to one or more embodiments it is not limited to the disclosed embodiments and that alternative embodiments could be constructed without departing from the scope of the invention as defined by the appended claims.
[0048] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention. | A motor vehicle having an instrument panel that is spaced rearward away from a bottom end of a windscreen so that it is less likely to be damaged in the event of a frontal impact. A cover is attached to vehicle body structure adjacent to the bottom end of the windscreen to cover the gap produced by spacing the instrument panel from the bottom of the windscreen. The cover overlies an upper surface of the instrument panel and slides rearward over the upper surface when the bottom end of the windscreen moves rearward into the crush space during a collision. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to agricultural implements, and more particularly to hydraulic load sensing systems of agricultural implements.
2. Description of the Related Art
Farmers utilize a wide variety of implements, including seeding implements such as drills and planters. In a known type of planting implement, seed planting or row units are attached to a toolbar extending transverse to the direction of planting. The toolbar is coupled to a tractor or other work vehicle suitable for pulling the planting implement along a field that is to be seeded to a crop. Each planting unit includes a ground penetrating assembly that shapes the bottom and sides of the seed trench, and a seed metering device provides individual seeds at a controlled rate for deposit in the seed trench. Furrow closing components of each row unit close the seed trench in a controlled manner.
The planter typically will have at least one hydraulic motor to run a fan for the movement of seed and at least one hydraulic seed drive motor, each having a variable hydraulic fluid use. These and other hydraulic fluid using devices on the implement use pressurized hydraulic fluid supplied by the tractor pulling the implement. The tractor may have a hydraulic pump with a variable output capability. The current art includes using hydraulic lines or hoses to communicate the load requirements to a control on the planter. This poses some difficulty to effectively do as the implements have increased in size requiring longer and longer hydraulic lines that have inherent losses and response delays.
What is needed in the art is a more cost effective and quicker response load control system for implements.
SUMMARY OF THE INVENTION
The present invention provides an implement load sensing and control system for an agricultural implement, and more particularly a planter having transducers that electronically resolve the load requirements.
In one form thereof, the invention is directed to an agricultural system including a tractor and an implement powered by the tractor. The implement having a plurality of hydraulic fluid using devices, at least one transducer, and a communications means. The transducer is configured to generate a signal representative of a hydraulic load requirement of the plurality of hydraulic fluid using devices. The communications means convey the signal to the tractor. The tractor is configured to alter a hydraulic fluid characteristic supplied to the implement dependent upon the signal.
In another form, the invention is directed to an agricultural implement powered by a tractor. The implement includes a plurality of hydraulic fluid using devices, at least one transducer, and a communications means. The transducer is configured to generate a signal representative of a hydraulic load requirement of the plurality of hydraulic fluid using devices. The communications means conveys the signal to the tractor. The tractor is configured to alter a hydraulic fluid characteristic supplied to the implement dependent upon the signal.
An advantage of the present invention is that the hydraulic load is quickly resolved and conveyed to the tractor.
Another advantage of the present invention is that it eliminates long hydraulic lines used for load control.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a perspective view of an agricultural seed planting implement;
FIG. 2 is a schematic representation of a load sense system and other elements in one embodiment of the present invention used on the implement of FIG. 1 ; and
FIG. 3 is a schematic representation of a load sense system and other elements in another embodiment of the present invention used on the implement of FIG. 1 .
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate embodiments of the invention and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, and more specifically to FIG. 1 in particular, a seed planting implement 10 is shown. Seed planting implement 10 has a frame that includes a tow bar assembly 12 having a tow bar 14 and a connection assembly 16 at the longitudinally forward end thereof configured for mating with a corresponding hitch of a tractor or other work vehicle (not shown) for pulling seed planting implement 10 through a field. A laterally extending toolbar 18 is generally transverse to tow bar 14 and thereby generally transverse to the direction implement 10 is towed during planting operations. A plurality of seed planting units (or row units) 20 are connected to toolbar 18 in a side by side relationship, each of the seed planting units (row units) being substantially identical to the others. In the exemplary embodiment shown, seed planting implement 10 includes sixteen seed planting units 20 , only some of which are identified with reference numbers; however, it should be understood that more or fewer seed planting units can be provided on a particular seed planting implement.
Each seed planting unit 20 is connected to toolbar 18 by upper and lower arms. Each seed planting unit 20 extends rearward from toolbar 18 to plant a row of seeds as seed planting implement 10 is towed across a field by tractor 22 . The individual planting units 20 are spaced along toolbar 18 to provide planted seed rows of a desired spacing. During a planting operation, forward movement of seed planting implement 10 causes each seed planting unit 20 to form a seed trench, deposit equally spaced seeds in the seed trench and close the seed trench over the deposited seeds.
A seed metering system receives seeds from a seed hopper and provides individual seeds at a controlled rate to a seed tube for deposit in the bottom of the seed trench. Bulk tanks 42 contain seed and perhaps fertilizer or chemicals that are metered to, or proximate to, the seed trench. A vacuum system includes a fan/motor 40 that provides vacuum to a seed metering system for the operation of the seed metering system. A seed trench closing mechanism 50 at the trailing end of each seed planting unit 20 closes the seed trench after the seeds have been deposited in the seed trench. Seed trench closing mechanism 50 may include a pair of pinch wheels that operate on opposite sides of the seed trench to move soil back into the seed trench and over the seeds deposited in the bottom of the seed trench. A trailing press wheel travels along the top of the closed seed trench and firms the soil replaced in the seed trench.
Now, additionally referring to FIGS. 2 and 3 there are shown schematical representations of two hydraulic load sensing systems 24 and 124 that resolve the highest load requirement and conveys that information to tractor 22 , which supplies pressurized hydraulic fluid to implement 10 based on the information.
Now looking at FIG. 2 , there is illustrated a hydraulic load sensing system 24 where a transducer 26 senses a load by having pressurized fluid from multiple parts of planter 10 conveyed thereto, through valves 34 . Illustrated here, there are seed drive motors 38 , and fan motors 40 in two different sections and a bulk fill fan 46 located at another section of implement 10 . These separate sections will have a load that requires a determinable amount of hydraulic fluid flow at a specific pressure to fulfil their individual load requirements. This load requirement is conveyed to transducer 26 by way of valves 34 , which may be shuttle valves or other suitable valves that will allow the highest load need to be conveyed to transducer 26 . Transducer 26 generates a signal representative of the load requirement and conveys the information by way of a communications means 36 represented here as a signal line 36 , to tractor 22 . The output of signal line 36 may be a synthesized hydraulic pressure that serves as the signal, particularly for the sake of compatibility with legacy tractor control systems.
In turn tractor 22 receives the signal from signal line 36 and uses that information to compensate the pressure and flow of the hydraulic fluid generated by a hydraulic pump coupled to an engine in tractor 22 , to thereby produce adequate power to run implement 10 . An advantage of the present invention is that the hydraulic needs of implement 10 can be met without the need to generate, by default, a constant higher pressure fluid supply. This reduces the energy losses that are experienced by less robust control systems.
Now, additionally looking at FIG. 3 , there is illustrated a hydraulic load sensing system 124 that has many of the same elements as system 24 . Here instead of having one transducer 26 , there are three transducers 28 , 30 and 32 , each respectively assigned to one of the sections previously discussed. In this embodiment of the present invention, each transducer 28 , 30 and 32 generates an individual signal, with them being electronically resolved to ultimately present one signal, by way of signal line 36 , to tractor 22 . The resolution of the signal is to present the highest result as the signal on signal line 36 . Signal line 36 may be an electronic signal conveyed by a wire, a wireless electronic signal, or the signal may be presented in some other medium, such as a fluid or air. More specifically, the signal from the transducer(s) is converted into a current command to a duplicator valve 48 at the front of planter 10 or on tractor 22 . The duplicator valve 48 uses supply oil from the power beyond line to create a duplicated hydraulic pressure signal the same as the highest load signal on the planter.
With the prior art the distance between the planter and the tractor is too long to provide a hydraulic hose between the load and the source to properly control a pressure compensated load sense system. In contrast the present invention uses pressure transducer(s) 26 , 28 , 30 and 32 , depending upon the embodiment, to capture the highest load pressure, and convert that to an electronic signal that is sent to a valve either on the front of planter 10 or on tractor 22 which can convert/duplicate that hydraulic pressure into the hydraulic load sense signal circuit.
These long distances between a prior art planter and tractor 22 make it difficult to use a hydraulic hose to effectively communicate the load signals between the planter and tractor. This prevents the signal being used to control the tractor and therefore taking advantage of the efficiencies available from a pressure flow compensating (PFC) load sensing system.
In the present invention pressure transducer 26 or a group of pressure transducers 28 , 30 and 32 are used by hydraulic load sensing system 24 or 124 at the toolbar of implement 10 . Depending on the pressure transducer used, the system pressure can be resolved hydraulically thru a chain of load sense check valves 34 which communicate to one transducer 26 , as in system 24 or a group of transducers 28 , 30 , 32 may be used, as in system 124 , with the highest pressure signal is resolved electronically at the controller. The oil supplied to the transducer controlled circuits on implement 10 will come from the power beyond connection on tractor 22 . The power beyond connections are a grouping of pump supply, return, and load sense signal inputs.
The pressure transducer (single or multiple arrangement) provides an electronic signal to the implement 10 controller 56 . Controller 56 converts the signal into a current command to the duplicator valve 48 at the front of planter 10 or on tractor 22 . The duplicator valve 48 uses supply oil from the power beyond line, or pump supply, to create a duplicated pressure signal the same as the highest load signal on the planter. The duplicated signal (if higher than the load sense signal circuit on the tractor) will communicate back to the PFC pump, thereby altering the hydraulic fluid pressure presented to implement 10 .
Duplicator valve 48 may be located in a valve manifold 52 coupled to implement 10 , or duplicate valve 48 may be located on tractor 22 . Valve manifold 52 is used to control power beyond flow. When tractor 22 is running power beyond is always pressurized and is able to flow oil. A solenoid operated check valve in valve manifold 52 blocks flow from getting out to the planter and running continuously.
While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims. | An agricultural system including a tractor and an implement powered by the tractor. The implement having a plurality of hydraulic fluid using devices, at least one transducer, and a communications device. The transducer is configured to generate a signal representative of a hydraulic load requirement of the plurality of hydraulic fluid using devices. The communications device conveying the signal to the tractor. The tractor is configured to alter a hydraulic fluid characteristic supplied to the implement dependent upon the signal. | 0 |
This application is a continuation-in-part of application Ser. No. 08/353,551 filed on Dec. 9, 1994, now abandoned
FIELD OF THE INVENTION
This invention relates to the field of immunology, in particular to vaccine compositions able to produce an autoimmune reaction against autologous (self) Epidermal Growth Factor (EGF).
An important object of this invention is to obtain a vaccine composition for the active immunotherapy of EGF dependent malignant tumors (e.g. epidermoid carcinoma of lung, glioblastoma multiforme and head and neck epidermoid carcinomas), which can inhibit the proliferation of those tumors, and which therefore are useful for the treatment of malignant neoplasms and of other EGF related diseases. Thus, the invention is also related to the field of cancer therapy.
DESCRIPTION OF THE PRIOR ART
Epidermal Growth Factor, a polypeptide that stimulates epithelial cell proliferation, has been considered to be one of the growth factors involved in malignant transformations. Its action is mainly performed via its membrane receptors.
Epidermal Growth Factor (EGF) is a 53 amino acid polypeptide, its molecular weight is about 6,045 D. It was isolated and purified for the first time from the murine submaxillary gland (Cohen S. J.Biol Chem (1962) 237,1.555). Later a similar molecule was obtained from human urine (Cohen S. Human Epidermal Growth factor: Isolation and Chemical and Biological Properties PNAS USA 72,1975 1 317).
EGF is capable of stimulating the proliferation of epithelial and mesenchymal cells, both in vitro and in vivo (Cohen S., Carpenter G., PNAS USA 72, 1317, 1975) and EGF gives a specific stimulation in some breast cancer cell lines (Osborne C. K. et al. Can Res. 40,2.361 (1980). A role of the EGF in the differentiation process of the mammary gland, mainly for the development of the lobule alveolar system has been demonstrated (Tonelli C. J. Nature (1980) 285, 250-252).
This bio-regulating action is exerted via a membrane receptor (EGF-R), a 1,186 amino acid glycoprotein of about 170 kD, the gene of which has been cloned and sequenced. The intracellular domain of the receptor is associated with an activity of Tyrosine specific protein kinase which shows a structural homology to the oncogene product v-erb-B showing the relation to the malignant transformation process (Heldin C. H. Cell 37, 9-20 (1984)).
EGF and its receptor constitute a molecular complex of high specificity and the interaction between them develops important mechanisms of cell growth regulation.
High levels of EGF-R have been detected in malignant tumors of epithelial origin, such as breast, bladder, ovarian, vulva, colonic, pulmonary, brain and oesophagus cancers. The role played by EGF and its receptor in regulating tumor growth is unknown, but there are suggestions that the EGF-R expression in tumor cells provides a mechanism for autocrine growth stimulation which leads to uncontrolled proliferation (Schlessinger J., Schreiber A. B., Levi A., Liberman T., Yarden Y. Crit. Rev. Biochem. 1983, 14 (2) 93-111).
The presence of EGF-R in tumor cells has proven to be an indication of a poor prognosis in human breast cancer. Approximately 40% of the breast tumors show specific binding sites of high affinity for EGF. There is also an inverse correlation with the presence of oestrogen receptor indicating EGF-R as a dedifferentiation marker or an indicator of the potential capacity of proliferation of the malignant cells (Perez R., Pascual M. R., Macias A., Lage A., Breast Cancer Research and Treatment 4, 189-193, 1984).
It also has been reported that the EGF-R expression is higher in regional ganglional metastases than in the primary breast carcinomas (Sainsbury J. R., et al. (1985): Lancet 1 (8.425), 364-366), and that the expression of the receptor is different in the different histologic subtypes of breast carcinomas cells, which also makes their presence a signal of bad prognosis (Macias A., et al. (1986); Anticancer Res.6: 849-852).
Previous studies performed in the Ehrlich Ascitic Tumor (EAT) model in Balb-C mouse, demonstrated the in vivo inhibitory effect of EGF (Lombardero J., et al. Neoplasma 33, 4 (1987), suggesting the possibility of considering this molecule as a biological response modifier.
The presence of an EGF precursor molecule has been previously reported in the cell membrane of EGF dependent tumors. The present inventors have reported it to be an important fact to consider this molecule as a target for the action of auto-antibodies.(Patent Application Cuba No. 113/93).
The results obtained in different studies, have prompted the consideration of the EGF/EGF-R system as a possible target for therapeutic actions.
Passive immunotherapy using monoclonal antibodies against the EGF-R, has been the object of multiple investigations, which have demonstrated that the specific recognition by the the antibody of the receptor inhibits the EGF binding, with an inhibitory effect on the mitogenic stimulation of malignant cells (SATO J. D., et al. Methods in Enzymology, vol. 146 pp 63-81, 1987), however; these antibodies which are of murine origin will usually produce a human anti mouse antibody response (HAMA).
Until the present invention, no active immunotherapy against EGF dependent tumors capable of inhibiting proliferation has been proposed, since the art consistently reports that "self" molecules will not induce any immune reaction because the host has been educated to be tolerant to self.
The present invention provides a vaccine composition containing autologous EGF coupled to a carrier protein, which complex will inhibit the EGF dependent tumors' growth, through an autoimmune effect, without the collateral effects of the introduction of a heterologous protein in the human body.
This vaccine composition can be used in the treatment of EGF dependent tumors or any malignant disease associated to EGF.
It will be understood that in this specification EGF is to be read as including any fragment and/or derivative of EGF which has similar immunological properties and/or effects as the original molecule. Derivatives include, but are not limited to, conventional amino acid substitutions, site-directed replacement of amino acids for enhanced stability and/or activity, chemical modifications and the like.
DETAILED DESCRIPTION OF THE INVENTION
I. OBTAINING AN IMMUNOGENIC PREPARATION
Several preparations were obtained, some based on murine EGF (mu-EGF) coupled to carrier proteins, others on human recombinant EGF (hu-rec-EGF) (National Medicament Register Office from Cuba, HEBERMIN, No.1266) coupled to carrier proteins (including monoclonal antibodies). The compositions were always administered through the parenteral route, subcutaneously.
The preparations containing mu-EGF conjugated to carrier proteins (such as Cholera toxin B chain and recombinant P64 as an example of an outer membrane protein from Neisseria meningitidis) were used in studies performed in mice as a model to determine the immunogenicity and the antitumoral effect of a vaccine preparation containing an autologous EGF molecule.
The preparations containing hu-rec-EGF coupled to carrier proteins were used in studies in non-human primates to determine their immunogenicity in a species more closely related to humans, as a necessary step preceding clinical use of the proposed vaccine preparations. A proper adjuvant was applied.
Immunogenicity studies were performed in primates with the conjugate hu-rec-EGF/carrier protein -! since the human EGF is very similar to the primate EGF though it is recognized as a self molecule. These results allowed demonstration of the immunogenic response an autologous molecule can elicit.
To obtain the preparations, a solution of murine or hu-rec-EGF in PBS/MgCl 2 10 mM, is mixed with a solution of the carrier protein in the same solvent, in a ratio of between 1 and 5 moles of EGF per mol of protein.
Afterwards glutaraldehyde 0.5% is added to obtain a final concentration between 0.1% and 0.05%.
The mixture is incubated between 1 and 3 hours at room temperature and subsequently dialyzed in PBS/Mgcl 2 10 mM with, at least, 3 changes of dialysis solution.
CONJUGATE CHARACTERIZATION
The test of the conjugation efficiency and of the maintenance of the antigenicity is performed through an ELISA assay.
ELISA plates of activated PVC (NUNC) were coated with 50 μl of an antiserum against the carrier protein utilized, in a concentration between 1 and 10 μg/ml. In the case of cholera toxin chain B (CTB) as carrier, the plates were coated with the ganglioside GMI.
Subsequently 3 washes with PBS/Tween were carried out; then the plates were blocked with a solution of BSA between 0.5 and 1% in PBS/Tween, and then incubated during a period of 30 minutes to 1 hour at 37° C. Dilutions between 0.1 and 0.001 mg/ml of the conjugates to be assayed were added to the plates, 50 μl/well, and incubated for 1 to 2 hours at 37° C.
In the next step a mouse anti hu-rec-EGF antiserum was added in a dilution between 1:500 and 1:1000, 50 μl/well, and incubated for between 30 minutes and 1 hour at 37° C.
As the last step, the plates were incubated with an anti-mouse-alkaline phosphatase antiserum, in a dilution between 1:500 and 1:1000, 50 μl/well, for 30 minutes to 1 hour at 37° C.
Reaction color was developed with p-nitrophenylphosphate, at a concentration of 1 mg/ml in diethanolamine, 50 μl/well, incubated for 30 minutes at 37° C. Optical density was measured at 405 nm in an ELISA plate reader.
The results demonstrated the activity of the molecule and the efficiency of the conjugation, because the conjugate maintains its recognition site for the molecule coating the plates, which specifically recognizes the carrier protein and, at the same time can be recognized by an anti EGF antiserum.
II. CHARACTERIZATION OF EFFECTS PRODUCED BY THE PREPARATION CONTAINING mu-EGF. PRE-CLINICAL STUDIES
IIa) ENDOGENOUS EGF IMMUNOGENICITY: INDUCTION OF AUTO-IMMUNITY IN MICE
In order to demonstrate the capacity of the immunogenic preparation containing mu-EGF obtained through the technique described in item I of inducing autoimmunity against the endogenous EGF, a test was performed in Balb/C mice.
Groups of animals were inoculated each week for 4 to 6 weeks with different doses in the range of 50 to 100 μg of mu-EGF conjugated to a carrier protein, per animal.
In the first week the immunogenic preparation was prepared in a ratio of 1:1 with complete Freund's adjuvant; all the following doses were prepared with incomplete Freund's adjuvant.
The same procedure was performed in a control group, but only adjuvant was administered to the animals. One week after the last immunization, blood was extracted from the animals, the serum separated from the remainder of the blood and the titer of antibodies against mu-EGF was determined by an ELISA technique.
IIb) IMMUNOGENICITY OF hu-rec-EGF
In order to demonstrate the immunogenicity of hu-rec-EGF in mice and to show that the antibodies against hu-rec-EGF recognize the mu-EGF, the experiment was performed in Balb/C mice.
Groups of animals were inoculated each week for 4 to 6 weeks with different doses in the range of 50 to 100 μg of hu-rec EGF-protein per animal.
In the first week the immunogenic preparation was prepared in a ratio of 1:1 with complete Freund's adjuvant; all the following doses were prepared with incomplete Freund's adjuvant.
The same procedure is performed in a control group, but only adjuvant is administered to the animals.
One week after the last immunization, blood was extracted from the animals, the serum was separated from the rest of the blood and the titer of antibodies against mu-EGF was determined by an ELISA technique.
IIc) ANTITUMOR ACTIVITY
The main objective of this experimental procedure is to determine whether the immune response obtained against the autologous EGF is able to elicit any antitumor effect in EGF dependent tumors.
The animals with higher antibody titer, determined according to the technique described previously, were inoculated with Ehrlich Ascitic Tumor (EAT) in cellular concentrations between 0.2 to 2 million cells per animal. The control group was treated in the same manner.
The animals were observed for grafting as well as for survival.
III. CHARACTERIZATION OF THE IMMUNE RESPONSE
IIIa) ISOTYPE OF THE ANTIBODY RESPONSE
In order to determine whether the autoimmune response obtained upon the immunization of mice with the autologous EGF is a response producing antibodies of the isotype IgM or IgG, an ELISA assay was performed testing the sera of immunized animals with EGF according to the techniques described in items II a) and b). In the case of IgM characterization an antiserum against this molecule was incubated with the samples. IgG characterization is performed with an antiserum against IgG.
IIIb) CHARACTERIZATION OF THE MEMORY OF THE IMMUNE RESPONSE
The development of a product to be used as a vaccine in an active therapy requires the determination of its capability of inducing an immunological memory and the determination of the duration of said memory if it is induced.
This information allows the possibility of a correct design of the immunization schemes that can be implemented with the product.
Groups of mice are immunized with one dose between 50 and 100 μg of hu-rec-EGF per animal in complete Freund's adjuvant in a proportion 1:1.
The kinetics of antibody production against mu-EGF was studied in different groups of animals. This study was performed after the first immunization and after the reimmunizations when the titer is declining. The antibody levels are determined using an ELISA technique.
IV. IMMUNOGENICITY STUDIES IN NON HUMAN PRIMATES
The criteria of immunogenicity of the immunogenic preparations to be used in humans are based on results obtained in non human primates because these are the species that are the closest to human.
A group of Rhesus monkeys (Macaca mulatta) are immunized with the immunogenic preparation containing hu-rec-EGF in a dose of 50 μg (conjugated with tetanic toxoid) and together with the adjuvant. After the last immunization blood samples were extracted and antibody titers against hu-rec-EGF were determined. This experiment provides information about the immunogenicity of the preparation of hu-rec-EGF coupled to tetanic toxoid and demonstrates that the response obtained is long lasting.
A group of Chimpanzees (Pan troglodytes) were immunized with hu-rec-EGF coupled to monoclonal antibodies as carrier proteins, in 4 doses of 50 μg of conjugated EGF, and together with adjuvant. After the last immunization, a blood sample was extracted and antibody titers against hu-rec-EGF were determined. This experiment provides information about whether the tested monoclonal antibodies could be used as carrier proteins in an EGF vaccine.
A group of Green monkeys (Cercopithecus aethiops) were immunized with hu-rec-EGF coupled to tetanic toxoid and to IOR-T3 monoclonal antibody in an immunization scheme of 2 doses of 50 μg of conjugated EGF adsorbed into Al(OH) 3 as adjuvant. After the last immunization a sample was extracted and antibody titers against hu-rec-EGF were determined. In this experiment we tested whether the immunization protocol proposed for use in clinical trials could induce antibody titers against the hu-rec-EGF contained in the tested vaccine preparations.
EXPERIMENTS
EXAMPLE 1
STUDY OF THE PRESENCE OF AN EGF PRECURSOR MOLECULE IN THE CELL MEMBRANE OF EGF DEPENDENT TUMORS
This study was performed through a Western Blotting technique. Samples of 5 ductal carcinomas of the breast in different stages, one head and neck tumor, four samples of fibrocystic dysplasia and five normal samples obtained as controls were studied.
Cell membranes were obtained from the samples through the procedure described elsewhere (Grimaux M., Rev. Neurol. 1988, 144: 101-103).
Electrophoresis was performed at 250 V, 10 mA, at 15° C. Molecular weight standards were used in the range of 14,300 D (Lysozyme) to 340,000 D (alpha 2 macroglobulin).
Proteins separated during electrophoresis were transferred to a nitrocellulose membrane of 0.45 μm in a Phast system equipment in a buffer transfer solution. After the transfer the membrane was blocked overnight with 10% skimmed milk with constant stirring.
After three washes in buffer solution a mouse monoclonal antibody recognizing human EGF was added and incubated during one hour.
After three washes a biotinylated anti-mouse antibody was added and incubated during one hour. Peroxidase streptavidine conjugate was added and reaction developed with diaminobenzidine and hydrogen peroxide after one hour of incubation.
The results obtained demonstrated that the samples studied corresponding to normal tissues did not show any band in the zone of high molecular weight according to the standards. However, the samples corresponding to breast pathology (dysplasia and carcinomas) showed a diffuse banding in the high molecular weight zone. This is an experimental evidence of the presence of a high MW EGF precursor in the tumor membranes.
EXAMPLE 2
OBTAINING THE mu-EGF/CTB CONJUGATE
One ml of mu-EGF in PBS/MgCl 2 10 mM at a concentration of 1 mg/ml, was mixed with 2 ml of a solution of CTB in the same solvent at a ratio of 1 mol of mu-EGF per mol of CTB. Glutar-aldehyde (3 ml, 0.5%) was added to obtain a final concentration of 0.05%.
Incubation was performed during 1 hour at room temperature and subsequently dialyzed in PBS/MgCl 2 10 mM with, at least, 3 changes of the dialysis solution.
EXAMPLE 3
mu-EGF/CTB CONJUGATED CHARACTERIZATION
ELISA assay for conjugate test: PVC activated ELISA plates (NUNC) were coated with 50 μl of the GM1 ganglioside (recognizing the CTB molecule) in a concentration of 4 μg/ml in methanol, which was left to dry off in the flow during 1 hour.
Subsequently 3 washes with PBS/Tween were carried out and then the plates were blocked with a solution of BSA 1% in PBS/Tween and incubated during 30 minutes at 37° C.
Conjugated dilutions between 0.1 and 0.001 mg/ml were added to the plates at 50 μl/well and incubated during 1 hour at 37° C.
Next a mouse anti-mu-EGF antiserum in a 1:1000 dilution, 50 μl/well was added and incubated for 1 hour at 37° C.
Then, the plates were incubated with anti-mouse antiserum alkaline phosphatase conjugate (dilution 1:1000), 50 μl/well for 1 hour at 37° C. The color was developed with p-nitrophenylphosphate at a concentration of 1 mg/ml in diethanolamine, 50 μl/well, incubated for 30 minutes at 37° C, optical density was measured at 405 nm.
The results demonstrated a direct relationship between the concentration of the conjugate and the absorbance values. This demonstrates the activity of the conjugate and the efficiency of the conjugation, since the molecule maintains the recognition for the GM1 ganglioside (identifies CTB) and, at the same time, is recognized by an anti mu-EGF antiserum (FIG. 1).
EXAMPLE 4
IMMUNOGENICITY OF AUTOLOGOUS EGF: INDUCTION OF AUTO-IMMUNITY IN MICE
In order to demonstrate that the immunogenic preparation containing autologous EGF is capable of inducing auto-immunity, experiments were performed in Balb/c mice.
Groups of animals were inoculated subcutaneously each week for 4 to 6 weeks with doses of 50 μg of conjugated mu-EGF per animal.
In the first week the immunogenic preparation was prepared in a proportion 1:1 with complete Freund's adjuvant; all the following doses were prepared with incomplete Freund's adjuvant.
The same procedure was performed in a control group, but only adjuvant was administered to the animals. One week after the last immunization, blood was extracted from the animals, the serum obtained and the titer of antibodies against mu-EGF was determined by an ELISA technique.
Costar plates were coated with mu-EGF at a concentration of 10 μg/ml in carbonate bicarbonate buffer (pH 9.6), and incubated overnight. After the plates were washed the samples were added in different dilutions. Incubation took place during one hour. Alkaline phosphatase anti-mouse antibody conjugate was added and incubated during one hour after which color was developed and optical density measured at 405 nm in an ELISA reader.
All the animals immunized with the mu-EGF-CTB preparation developed antibody titer against the mu-EGF up to 1:1000 dilution. The control group did not show any antibody titer (FIG. 2).
EXAMPLE 5
IMMUNOGENICITY OF hu-rec-EGF: INDUCTION OF AUTO-IMMUNITY IN MICE
In order to demonstrate that the immunogenic preparation containing hu-rec-EGF was capable of producing antibody titer against mu-EGF, experiments were performed in Balb/c mice.
Groups of animals were inoculated with doses of 50 μg of hu-rec-EGF per animal subcutaneously, each week for 4 to 6 weeks.
In the first week the immunogenic preparation was prepared in a proportion 1:1 with complete Freund's adjuvant; all the following doses were prepared with incomplete Freund's adjuvant.
The same procedure was performed in a control group, but only adjuvant was administered to the animals.
One week after the last immunization, blood was extracted from the animals, the serum obtained and the titer of antibodies against mu-EGF was determined by an ELISA technique.
Costar plates were coated with mu-EGF at a concentration of 10 μg/ml in carbonate bicarbonate buffer (pH 9.6), and incubated overnight. After the plates were washed the samples were added in different dilutions. Incubation took place during one hour. The alkaline phosphatase anti-mouse antibody conjugate was added and incubated during one hour after which color was developed and optical density measured at 405 nm in an ELISA reader.
All the animals immunized with the hu-rec-EGF preparation developed antibody titer against the mu-EGF up to 1:20000 dilution.
The control group did not show any antibody titer (FIG. 3).
EXAMPLE 6
IMMUNOGENICITY OF hu-rec EGF IN A PREPARATION WITH ALUMINUM HYDROXIDE
In order to demonstrate that the immunogenic preparation containing hu-rec-EGF and aluminium hydroxide as adjuvant was capable of producing antibody titer against mu-EGF, experiments were performed in Balb/c mice.
Groups of animals were inoculated with doses of 50 μg of hu-rec-EGF (with aluminum hydroxide as adjuvant) per animal subcutaneously, each week for 4 to 6 weeks.
The same procedure was performed in a control group, but only adjuvant was administered to the animals. One week after the last immunization, blood was extracted from the animals, the serum obtained and the titer of antibodies against mu-EGF was determined by an ELISA technique.
Costar plates were coated with mu-EGF at a concentration of 10 μg/ml in carbonate bicarbonate buffer (pH 9.6), and incubated overnight. After the plates were washed the samples were added in different dilutions. Incubation took place during one hour. The alkaline phosphatase anti-mouse antibody conjugate was added and incubated during one hour, after which color was developed and optical density measured at 405 nm in an ELISA reader.
All the animals immunized with the hu-rec-EGF/aluminium hydroxide preparation developed antibody titer against the mu-EGF up to 1:4000 dilution.
The control group did not show any antibody titer (FIG. 4).
EXAMPLE 7
ANTI-TUMOR ACTIVITY
The main objective of this experimental procedure was to determine whether the immune response obtained against the autologous EGF was able to elicit any antitumor effect in EGF dependent tumors.
The immunized animals with higher antibody titer, determined according to the technique described previously in example 5, were inoculated with Ehrlich Ascitic Tumor (EAT) in cellular concentrations of 2 million cells EAT per animal. The control group (non-immunized mice) was treated in the same manner.
The animals were observed for grafting as well as for survival. Survival curves of treated and control animals are shown in FIG. 5.
The Increase in Life Span Index was 22.5% showing an increase in survival for the treated animals in relation to the control statistically significant according to the Mantel Haenszel and Wilcoxon tests.
EXAMPLE 8
ASSOCIATION BETWEEN ANTIBODY TITER AGAINST mu-EGF AND 125 I EGF BIODISTRIBUTION
This experiment was performed to demonstrate that there is a different biodistribution of 125I EGF in animals with antibody titer against mu-EGF in relation to animals that did not have antibody titer against mu-EGF.
An experiment with 4 groups of mice was performed for this purpose:
Group 1: 30 mice with antibody titer against mu-EGF.
Group 2: 30 mice without antibody titer against mu-EGF.
Group 3: 30 mice with antibody titer against mu-EGF grafted with EAT.
Group 4: 30 mice without antibody titer against mu-EGF grafted with EAT.
Samples from group 1 and 2 were taken from blood, lung, kidneys, liver and skin at the following times: 2, 5, 8, 11, 15, 20, 30, 60, 120 and 150 minutes and 3 animals were sacrificed at every corresponding time, counting the radioactivity in the organs extracted.
The results obtained have shown a difference in the accumulation of 125 I-EGF in time mainly in kidney and liver (FIG. 6a,b), indicating that the presence of antibodies against EGF alters the biodistribution of this molecule.
Samples from group 3 and 4 were taken from blood, lung, kidneys, liver, skin and from the ascitic fluid at the following times: 2, 5, 8, 11, 15, 20, 30, 60, 120 and 150 minutes and 3 animals were sacrificed at every corresponding time, and the radioactivity counted in the organs extracted.
Less accumulation of the labelled EGF was observed in the ascitic fluid of animals with antibody titer than in the animals without antibody titer (FIG. 7), indicating a more rapid depuration of the EGF present in the ascitic fluid in these animals and/or a limitation in EGF access to the ascites.
EXAMPLE 9
IMMUNE RESPONSE CHARACTERIZATION: ISOTYPE OBTAINED AGAINST AUTOLOGOUS EGF
In order to know whether the autoimmune response obtained upon the immunization of mice with the autologous EGF was a response producing antibodies of the isotype IgM or IgG, an ELISA assay was performed in which the plates were coated with EGF to a concentration of 10 μg/ml, 50 μg/well, and incubated for 1 hour at 37° C.
Subsequently, dilutions between 1:10 and 1:1000 of the sera of animals immunized with mu-EGF-CTB according to Example 5 were applied, 50 μg/well, and were incubated for 1 hour at 37° C.
A parallel design of microtiter plates was applied to measure IgG or IgM response with the corresponding antiserum (anti-IgG or anti-IgM respectively).
Color in the plates was developed with p-nitrophenyl phosphate, at a concentration of 1 mg/ml in diethanolamine, incubating during 30 minutes at 37° C and values of optical density at 405 nm were read.
IgG response was obtained in all treated animals (FIG. 8).
EXAMPLE 10
CHARACTERIZATION OF THE MEMORY OF THE IMMUNE RESPONSE AGAINST AUTOLOGOUS EGF
Two groups of 10 mice were studied with a single immunization of 50 μg hu-re-EGF in complete Freund's adjuvant. Group I.--The kinetics of antibody production against mu-EGF was studied in this group of animals. Every 4 days blood samples were extracted. The antibody levels were determined by an ELISA technique. Group II.--This group consisted of animals immunized at the same time as animals of Group I. These animals were re-immunized when antibody titers were declining (as was known by the determination of titers in Group I), and then every 2 days blood samples were extracted. The antibody levels were determined by an ELISA technique.
Results have shown a memory response when the animals were re-immunized with the preparation, after the decrease in the antibody titers developed with the first immunization (FIG. 9).
EXAMPLE 11
OBTENTION OF THE IMMUNOGENIC PREPARATION: hu-rec-EGF/TETANIC TOXOID
A solution of hu-rec-EGF in PBS/MgCl 2 10 mM at a concentration of 1.4 mg/ml, was mixed with 2 ml of a solution of TT in the same solvent at a concentration of 4 mg/ml. Glutaraldehyde (3 ml, 0.5%) was added to obtain a final concentration of 0.05%.
Incubation was performed during 1 hour at room temperature and subsequently dialysed in PBS/MgCl 2 10 mM with, at least, 3 changes of the dialysis solution.
EXAMPLE 12
CONJUGATE CHARACTERIZATION: hu-rec-EGF/TETANIC TOXOID ELISA assay for conjugate test
Costar plates (High Binding) were coated with 50 μl of an anti-TT antiserum obtained in sheep, in a concentration of 10 μg/ml and incubating it overnight.
Subsequently 3 washes with PBS/Tween were carried out and then the plates were blocked with a solution of BSA 1% in PBS/Tween, and incubated during 30 minutes at 37° C.
Conjugate dilutions between 0.1 and 0.001 mg/ml were added to the plates at 50 μl/well, and incubated during 1 hour at 37° C.
Next a mouse anti-hu-rec-EGF antiserum in a 1:1000 dilution, 50 μl/well was added, and incubated for 1 hour at 37° C.
Then, the plates were incubated with anti-mouse antiserum alkaline phosphatase conjugate (dilution 1:1000), 50 μl/well for 1 hour at 37° C. The color was developed with p-nitrophenylphosphate at a concentration of 1 mg/ml in diethanolamine, 50 μl/well, incubated for 30 minutes at 37° C, and optical density was measured at 405 nm.
The results demonstrated a direct relationship between the concentration of the conjugate and the absorbance values.
This demonstrates the activity of the conjugate and the efficiency of the conjugation, since the molecule maintains the recognition for anti-TT antiserum and, at the same time, is recognized by an anti-mu-EGF antiserum (FIG. 10).
EXAMPLE 13
STUDY OF THE IMMUNOGENICITY OF hu-rec-EGF COUPLED TO A CARRIER PROTEIN (TT) IN NON-HUMAN PRIMATES
The study was performed with 4 Rhesus monkeys (Macaca mulatta), being submitted to a clinical veterinary examination including:
Physical examination,
Thorax X rays,
Blood tests.
These animals were immunized with a hu-rec-EGF coupled to TT, according to Example 10.
Immunization was performed subcutaneously in weeks 1, 2, 3, 4, 6 and 12. Complete Freund's adjuvant was used in the first immunization and incomplete Freund's adjuvant in all others.
Blood was extracted from the animals and antibody titers were determined through an ELISA.
Costar plates were coated with hu-rec-EGF at a concentration of 10 μg/ml in carbonate bicarbonate buffer (pH 9.6), and incubated overnight. After the plates were washed the samples were added in different dilutions. Incubation took place during one hour. The alkaline phosphatase anti-human antibody conjugate was added and incubated during one hour after which color was developed and optical density measured at 405 nm in an ELISA reader.
All the animals immunized with the hu-EGF-TT preparation developed antibody titer against the hu-EGF up to 1:200000 dilution (FIG. 11). A long lasting immune response was observed.
EXAMPLE 14
STUDY OF P64 PROTEIN AS CARRIER MOLECULE IN EGF VACCINE, INDUCTION OF AUTOIMMUNITY IN MICE
Recombinant P64 (membrane protein of Neisseria meningitidis) was purchased from the Center of Genetic Engineering and Biotechnology of Havana. It is described in U.S. Pat. No. 5,286,484.
A conjugate between murine EGF and P64 protein was obtained using the glutaraldehyde conjugation method.
In order to demonstrate that the immunogenic preparation containing autologus EGF and P64 as carrier protein is capable of inducing autoimmunity, experiments were performed in Balb C mice.
Groups of animals were immunized subcutaneously with 10 μg/g of mu-EGF coupled to P64, twice, with a weekly frequency. In the first week the immunogenic preparation was prepared in a proportion 1:1 with Freund's complete adjuvant and in the second week in the same proportion with incomplete Freund's adjuvant. A control group was included of mice treated only with adjuvant.
Three weeks after the first immunization, serum was obtained and the titers against autologus EGF determined by an ELISA.
Costar plates were coated with mu-EGF at a concentration of 10 μg/ml in carbonate bicarbonate buffer (pH 9.6) and incubated overnight. After the plates were washed the samples were added in different dilutions. Incubation took place during one hour. Alkaline phosphatase anti-mouse antibody conjugate was added and incubated during one hour after which color was developed and optical density measured at 405 nm in an ELISA reader.
All animals immunized with the mu-EGF-P64 preparation developed antibody titers against the mu-EGF between 1:100 and 1:500 sera dilution. The control group did not show any antibody titer (FIG. 12).
EXAMPLE 15
STUDY OF IOR-T3 AND IOR-CEA1 AS CARRIER MOLECULES IN EGF VACCINE
IOR-T3 is a IgG2a monoclonal antibody that recognizes human T lymphocytes and IOR-CEA1 is a IgG1 monoclonal antibody that recognizes carcinoembryonic antigen. Both were tested as carrier protein in two vaccine preparations of EGF.
IOR-T3 and IOR-CEA1 were produced in the Center of Molecular Immunology of Havana.
Conjugates between hu-rec-EGF and both monoclonal antibodies were obtained using the glutaraldehyde conjugation method.
The study was performed in 3 chimpanzees (Pan troglodytes) which were submitted to a clinical veterinary examination including:
Physical examination,
Thorax X rays,
Blood tests.
Two of these monkeys were immunized either with hu-EFG coupled to IOR-T3 or with hu-EGF coupled to IOR-CEA1, with 4 doses of 50 μg of conjugated EGF. A control monkey was immunized with hu-EGF without coupling to any carrier protein, 4 doses of 50 μg. Immunizations were performed subcutaneously in weeks 1, 2, 3 and 4. Complete Freund's adjuvant was used in the first immunization and incomplete Freund's adjuvant in all others.
Blood was extracted from the animals on days 0, 14, 28, 42 and 56, and the antibody titers were determined in serum through an ELISA.
Costar plates were coated with hu-EGF at a concentration of 10 μg/ml in carbonate-bicarbonate buffer (pH 9.6), and incubated overnight. After the plates were washed the samples were added in different dilutions. Incubation took place during one hour. The alkaline phosphatase anti-human antibody conjugate was added and incubated during one hour, after which color was developed and optical density measured at 405 nm in an ELISA reader.
The monkeys immunized with hu-EGF coupled to IOR-T3 or to IOR-CEA1 developed antibody titers against hu-EGF, the control monkey did not. The developed titers are shown in FIG. 13.
EXAMPLE 16
IMMUNOGENICITY IN MONKEYS OF DIFFERENT VACCINE PREPARATIONS OF EGF USING AL(OH) 3 AS ADJUVANT
In order to test in non-human primates vaccine preparations in an adequate formulation to be used in future clinical assays, experiments were performed in Green Monkeys (Cercopithecus aethiops).
The study was performed in 6 primates, being submitted to a clinical veterinary examination including:
Physical examination,
Thorax X rays,
Blood tests.
The vaccine preparations tested were:
1. hu-rec-EGF coupled to tetanic toxoid (as described before), 50 μg of conjugated EGF per dose in 2 ml of final volume, adsorbed in Al(OH) 3 (2 mg per dose) for 3 hours at room temperature. Two monkeys were immunized with this preparation.
2. hu-rec-EGF coupled to IOR-T3 monoclonal antibody through the glutaraldehyde technique, 50 μg of conjugated EGF per dose in 2 ml of final volume, adsorbed in Al(OH) 3 (2 mg per dose) for 3 hours at room temperature. Two monkeys were immunized with this preparation.
3. hu-rec-EGF without coupling to any carrier protein as negative control in the experiment, 50 μg per dose, in 2 ml of final volume, adsorbed in Al(OH) 3 in the same way. Two monkeys were immunized with this preparation.
The immunization protocol was of two doses on days 0 and 14, and the product was administered subcutaneously.
Blood was extracted on days 0, 30 and 60 and serum tested for antibody titers against hu-EGF through an ELISA.
Costar plates were coated with hu-rec-EGF at a concentration of 10 μg/ml in carbonate-bicarbonate buffer (pH 9.6) and incubated overnight. After the plates were washed the samples were added in different dilutions. Incubation took place during one hour. The alkaline phosphatase anti-human antibody conjugate was added and incubated during one hour after which color was developed and optical density measured at 405 nm in an ELISA reader.
Monkeys immunized either with hu-EGF/TT or with hu-EGF/IOR-T3 developed antibody titers against hu-EGF as is shown in FIG. 14.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1: ELISA assay for determination of conjugation efficiency between CTB and mu-EGF.
x axis: serial dilutions of the conjugate (from 0.1 mg/ml to 0.001 mg/ml);
y axis: optical density at 405 nm, measured in an ELISA plates reader.
FIG. 2: ELISA assay for the determination of antibody titer against the mu-EGF in 5 mice immunized with the conjugated mu-EGF-CTB.
x axis: Antiserum dilutions (1:10, 1:100, 1:1000);
y axis: optical density at 405 nm, measured in an ELISA plate reader.
The curves represent the titer of 5 tested animals, compared with the same animals before immunization.
FIG. 3: ELISA assay for the determination of antibody titer against mu-EGF, in 5 mice immunized with hu-rec-EGF.
x axis: sera dilutions 1:100, 1:1000, 1:10000, 1:20000;
y axis: optical density at 405 nm.
FIG. 4: ELISA assay for the determination of antibody titer against mu-EGF, in 5 mice immunized with hu-rec-EGF in aluminum hydroxide as adjuvant
x axis: sera dilutions 1:100, 1:500, 1:1000, 1:2000, 1:4000, 1:8000;
y axis: optical density at 405 nm.
FIG. 5: Survival of animals immunized with mu EGF-CTB and subsequently inoculated with Ehrlich Ascites tumour, in comparison with control animals (non-immunized) and inoculated with the same tumor.
FIG. 6-a: Accumulation of 125 I-EGF in liver of mice immunized with hu-rec-EGF in relation to non-immunized controls.
x axis: time in minutes;
y axis: percent of incorporated dose of radioactivity per gram of tissue.
FIG. 6-b: Accumulation of 125 I-EGF in kidneys of mice immunized with hu-rec-EGF in relation to non-immunized controls.
x axis: time in minutes;
y axis: percent of incorporated dose of radioactivity per gram of tissue.
FIG. 7: Accumulation of 125 I-mu-EGF in ascitic fluid of animals grafted with EAT, previously immunized with hu-rec-EGF.
FIG. 8: ELISA assay for determination of IgG or IgM of the immune response in animals immunized with mu-EGF-CTB.
FIG. 9: Antibody response kinetics (IgG) against mu-EGF in animals immunized against hu-rec-EGF (Memory).
x axis: time (days);
y axis: Inverse logarithm of the antibody titer.(mean value).
FIG. 10: ELISA assay for the determination of the efficiency of conjugation of Tetanic toxoid with hu-rec-EGF.
x axis: dilutions of conjugate;
y axis: optical density at 405 nm.
FIG. 11: antibody titer against hu-rec-EGF in non-human primates immunized with hu-rec-EGF, coupled to tetanic toxoid.
FIG. 12: Antibody titers against autologous EGF in mice immunized with murine EGF coupled to P64 carrier protein.
x-axis: mice sera dilutions;
y-axis: optical density at 405 nm.
FIG. 13: Antibody titers against hu-rec-EGF in Chimpanzees (Pan troglodytes), one immunized with hu-rec-EGF coupled to IOR-T3 monoclonal antibody and the other with hu-rec-EGF coupled to CEA monoclonal antibody, using Freund's complete adjuvant. A negative control was included of a monkey immunized only with hu-rec-EGF in Freund's adjuvant.
FIG. 14: Antibody titers against hu-rec-EGF in Green monkeys (Cercopithecus aethiops), immunized with hu-rec-EGF coupled to IOR-T3 monoclonal antibody and with hu-rec-EGF coupled to tetanic toxoid, using Al(OH) 3 as adjuvant. A negative control was included of two monkeys immunized with hu-rec-EGF in Al(OH) 3 adjuvant. | The invention provides novel uses of EGF and vaccine compositions comprising EGF. In particular, autologous EGF, or a fragment or a derivative thereof, is used as an active immunization against the proliferation of EGF-dependent tumors, or other EGF-dependent diseases. Autologous EGF is preferably coupled to a carrier protein, such as tetanus toxoid or Cholera toxin B chain. The vaccine compositions according to the invention will usually comprise an adjuvant such as aluminum hydroxide. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/190,810, entitled A WIDGETIZED AVATAR AND A METHOD AND SYSTEM OF CREATING AND USING SAME, filed on Sep. 2, 2008 and naming inventor Robb Fujioka, which application is hereby incorporated by reference herein as if set forth in the entirety.
FIELD OF THE INVENTION
[0002] The present invention is directed to avatars for use in computing communities and, more particularly, to a widgetized avatar and a method and system of creating and using same.
BACKGROUND OF THE INVENTION
[0003] Many computing and entertainment embodiments allow for a user, player, or viewer to create an “avatar.” An avatar is typically a virtual manifestation of that user's “computerized physicality.” However, the prior art typically provides only limited options for a user who wishes to create an avatar, such as limited physical features, clothing, associated information, and the like. As such, a typical avatar allows for only very limited information about a user to be relayed by the avatar. More specifically, the physical characteristics of the avatar likely have only limited applicability to the physicality of the real-world user, due in part to the limited physical, clothing and the like options available in creating the avatar, and the typical information associated with the avatar, other than its physicality, is limited or nonexistent.
[0004] Additionally, present avatars need to be created over and over again, and are highly variable for the same real user as between different applications using an avatar, in principal part because avatars are not typically transferable as between multiple applications. Further, present avatars present little or no monetization or marketing opportunities, nor do present avatars allow for collection of, or provision to, potential transaction partners of the preferences, characteristics or interests of the actual user.
[0005] Thus, the need exists for an avatar, and an apparatus, system and method related thereto, that allows for transferability, improved physical relation to the actual user, more information regarding the actual user, and improved marketing, monetization and transaction opportunities related to the user's avatar.
SUMMARY OF THE INVENTION
[0006] An avatar system and method of disclosed. The avatar includes computing code that provides for addition of the avatar as non-static content to at least two unique at least partially static web pages, and secondary computing code resident within the computing code, wherein the secondary computing code provides for association with at least one other portion of the computing code of: ones selected from a plurality of physical characteristics, a plurality of personal information, and a plurality of actions.
[0007] An avatar trading card system and method is also disclosed. This card includes a front of the avatar trading card including an avatar, a back of the avatar trading card including a selectable display for display of categorized information, wherein at least a portion of the categorized information is associated with one or more subjects of the avatar, and a toggle that provides for a toggle between the back and the front, wherein the selectable display provides selectability of categorized information.
[0008] A method of configuring an online persona is also disclosed. The method includes creating an avatar representative of a likeness of a computer user, and configuring the created avatar by: modifying a first set of visible attributes, and accepting a first set of identifying information that is linked to the first set of visible attributes, modifying a second set of visible attributes, and accepting a second set of identifying information that is linked to the second set of visible attributes, wherein the accepting of the first set of identifying information increases a number of available ones of the first set of visible attributes, and wherein accepting the second set of identifying information increases a number of available ones of the second set of visible attributes.
BRIEF DESCRIPTION OF THE FIGURES
[0009] Understanding of the present invention will be facilitated by consideration of the following detailed description of the preferred embodiments of the present invention taken in conjunction with the accompanying drawings, in which like numerals refer to like parts:
[0010] FIG. 1 illustrates an avatar in accordance with the present invention; and
[0011] FIG. 2 illustrates an avatar in accordance with the present invention;
[0012] FIG. 3 illustrates an avatar in accordance with the present invention;
[0013] FIG. 4 illustrates a plurality of avatars in accordance with the present invention; and
[0014] FIG. 5 illustrates a flow diagram in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] It is to be understood that the figures and descriptions of the present invention have been simplified to illustrate elements that are relevant for a clear understanding of the present invention, while eliminating, for the purpose of clarity, many other elements found in typical avatar and computing apparatuses, systems and methods. Those of ordinary skill in the art may recognize that other elements and/or steps are desirable and/or required in implementing the present invention. However, because such elements and steps are well known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such elements and steps is not provided herein. The disclosure herein is directed to all such variations and modifications to such elements and methods known to those skilled in the art.
[0016] An avatar is understood by one of ordinary skill in the art to include a computer user's representation of him or herself, or a single or multiple characteristics thereof, such as in the form of a two or three dimensional model used in computer games, social network applications, or other on-line communities. A typical avatar may further include, or have associated therewith, a user's name, a user's screen name, a handle, or text of interest, such as a trademark, saying, or poem, for example.
[0017] A widget in accordance with the present invention, and as will be understood by one of ordinary skill in the art, is a portable portion of code that may be installed or executed within any separate HTML based webpage by an end user without necessitating additional compilation of that code portion. Such widget code portions, in accordance with the present invention, are embeddable by the end user. As such, a widget in accordance with the present invention is any code portion that may be embedded by the end user within a selected page of HTML, XML, or like code that causes presentation of that selected web page. The widget, via the embedded code portion, thereby adds non-static content to the subject webpage.
[0018] The present invention includes a fully portable, widgetized avatar having associated therewith multiple items of social information that are generally requested for association with at least two different computing communities or transactions. Widgetization of the avatar of the present invention necessarily allows for portability of the avatar of the present invention. For example, creation of a typical avatar in accordance with the present invention may include the association of physical, such as facial and hair, features with the subject avatar, as well as the aforementioned user name, as shown in FIG. 1 . As may be seen in FIG. 1 , an avatar creator may be used to create an avatar in a likeness of a user, such as a computer user's representation of him or herself, such as based on a single or multiple characteristics thereof. For example, user may select either a male or female avatar base. The user may select a skin tone of the avatar, such as to represent the user's skin tone. The creator of FIG. 1 may also be used to set a head profile and/or shape, an eye configuration and/or eye type, eyebrows, mouth, nose, ears and the like. Additionally, hair may be added to the avatar and the color, hair type, and general appearance of the hair may be configured. The avatar may also be outfitted in a clothing ensemble, and other type of accessories and/or clothing and the like will be discussed below. By way of non-limiting example headwear, shirts, pants, shorts, jewelry and other accessories, shoes and belts may be added to the created avatar as illustration in FIG. 1 .
[0019] Further, a myriad of additional information may be associated with the avatar, wherein such information may be for use in computing communities or transactions. This information may be organized into multiple levels of detail, and/or multiple levels of accessibility to third parties in a computing community or transaction, for example. Such levels of a accessibility may be selected by the creator of the widgetized avatar based on characteristics of the third party endeavoring to access the subject avatar. For example, a user may have basic information, which may be selectable for viewing by all registered users of a particular community, as shown in FIG. 2 .
[0020] In an exemplary embodiment, a user may have likes or dislikes, such as musical or motion picture tastes, job or educational status, age, location, income, marital status, and other computed communities with which that user is associated, associated with his or her avatar. The present invention provides a physical manifestation of all of this information, such as in a “trading card” format. For example, FIG. 2 illustrates an avatar wherein the front of the virtual trading card includes an avatar having particular physical features, clothing, accessories, activities, and the like, along with an associated user name. Additionally, on the front of the virtual trading card may be found commonly used links, such as the most commonly used among those links accessible through other aspects of the avatar or virtual trading card. This may include links to photos, avatar accessories, avatar features, movies, and the like, as shown.
[0021] For example, links on front of the virtual trading card may be populated by counting the number of times that a link is accessed by a user, and placing the top four, for example, on the front of the virtual trading card. Other mechanisms to populate the front of the trading card may also be used, such as allowing an advertiser to populate a spot, the user to populate a spot, the site from which the avatar was created to populate a spot, the fourth spot to be rotated by popularity for a given day, for example. These techniques may be combined to populate the front of the virtual trading card. While four spots have been discussed herein, any number of locations of the front of the card may be used, including any number of locations at the bottom, top and sides, for example.
[0022] When an interaction, such as selection of a drop-down menu, selection of a link, a double click, or the like is undertaken to “flip” a trading card to the back, a myriad of additional information may be displayed regarding the user related to the widgetized avatar, such as age, interests, likes and dislikes, employment status, and the like. The back of the virtual trading card may include links to a profile, interests, links, photos, friends, pokes, connections and style, by way of non-limiting example only. Each such link may provide information associated therewith. As shown in FIG. 2 , a interaction, such as a click, for example, of the profile link may provide profile information for the user of the avatar, including but not limited to, name, sex, birthday, hometown and/or, address. More advanced profiles may also be initiated by dropdown menu, and may include credit card information, preferred websites, products that have been viewed or purchased, and other similar information.
[0023] Needless to say, because the virtual manifestation of the physical trading card is embodied in the computing code that provides for the virtual manifestation, such computing code may be provided in a normalized format that it is easily adopted into multiple computing communities, and/or may be adopted as non-static content onto multiple different web pages. As such, the subject avatar may be incorporated into multiple social communities, fantasy sports communities, blogs, and the like. In fact, tools to create such widgetized avatars may be accessible from, or provided within, such social communities, blogs, and the like. Further, avatars of particular interest to the general public, such as trading card avatars of musical artists or other famous persons, may be downloaded or referenced by fans of such famous persons. Such avatars may, in fact, be presented in non-classical formats, such as through a tab presentation on a web page designed by the user as a home page in a certain community, or that is set forth by a particular computing community. Such “celebrity” avatars, including in such non-classical formats, may include presentations or allow for interactions with celebrity suggestions or favorites, such as recipes, music, concerts, movies, talk shows, reality shows, or the like, and may further allow for purchases from or related to such suggestions or favorites.
[0024] As referenced hereinabove, a typical avatar may have associated therewith certain physical features, clothing, accessories or activities. As such, the present invention is and includes a tool whereby such physical features, clothing, accessories, and activities may be taken from the real world and “virtualized”, for use with a subject avatar, as shown in FIG. 3 . For example, famous clothing lines, such as Vera Wang clothing, or famous shoe lines, such as Nike sneakers, or famous accessories, such as Kate Spade purses, or well known activities, such as playing for the Philadelphia Phillies, may be virtualized for use with an avatar. As such, virtualized items may be made available for sale for use with an avatar just as the corresponding real items are generally for sale for use with the real world user correspondent to the avatar. As may be seen in FIG. 3 , an avatar may be outfitted with a hat, sunglasses, tie, belt and shoes to create the fashioned avatar. Similarly, another avatar may be outfitted with a headscarf, necklace, earrings, purse and boots to create a fashioned avatar. Such outfitted avatars are discussed herein by way of non-limiting example only, and thus any real world configuration of attire may be included in a fashioned avatar.
[0025] Likewise, celebrity avatars may be presented as “model” widgetized avatars, and the user may be enabled to purchase those items worn by the celebrity's avatar, and/or that are endorsed by that celebrity, as shown in FIG. 4 . As may be seen in FIG. 4 , a gallery of characters may be provided. The gallery may include artists, athletes, actors, musicians, actresses, and may include individualized characters, such as colleagues in a work environment, for example. These characters may include likenesses of the respective public figures and may also include accessories to further identify the public figure.
[0026] Thereby, for example, during creation of a discreet widgetized avatar and/or a widgetized avatar to be associated with the aforementioned avatar trading card, the user creating the avatar may have available a selectable library of options for association with the subject avatar, such as a searchable library of options searchable by key word, or a hierarchal library of options presented by topic. For example, under “fashion”, a user may be presented with available virtual clothing lines for the avatar by piece of clothing. For example, under “shirts”, the user may be presented with options such as Jones New York, Tommy Hilfiger, Fubu, Major League Baseball, National Football League, and the like. The user may then select one of the presented fashion topics for shirts, and then may be presented with the entire line of “real world” shirts associated with that fashion line, but, of course in a virtualized format. Thus, for example, upon selection of Major League Baseball, the user may be presented with a series of major league baseball team jerseys for association with that user's avatar. Needless to say, the user may then select the baseball jersey of that user's favorite team, and may in fact pay for the use of that virtual jersey just as the user might pay for the purchase of a real world jersey of that user's favorite baseball team. Similarly, fashion lines of pants, dresses, suits, shoes, and the like may be made available for use with avatars, and may in fact be made available for purchase by users for use with avatars. Likewise, accessories or activities that would require purchase in the real world by the user may additionally allow for purchase of such accessories or activities in the virtual world for use with the user's widgetized avatar.
[0027] Additionally, the present invention may provide an upsell engine as illustrated in FIG. 5 . The upsell engine may operate, upon purchase of a virtual item for association with the user's avatar, may present the user with an opportunity to purchase the same or similar article in the real world for real world use by the actual user based on that user's known preference for that article as evidenced by the purchase of the virtual article for use with the user's avatar. The upsell engine may additionally or alternatively include presentation to the user of an advertisement for real world articles that are the same as or associated with the virtual article purchased by the user, or may allow for presentation of advertising related to likely related virtual or real world articles of interest to the user based on the user's expressed preference for the particular virtual article selected. Needless to say, the present invention may also be used to upsell in the inverse situation—that is, the situation in which the user purchases a real world article from a particular web site, or surfs a particular web site for real world goods and/or services, may cause the user to be presented with advertising for the purchase of the same or similar virtual articles, or associated or related virtual articles, or to be presented with a direct opportunity to purchase the same, similar, or related virtual articles at the point of purchase of the particular real world article.
[0028] Similarly, games, rewards, or the like may be made available to, or via, the aforementioned avatars. For example, when certain objectives are achieved, such as in a gaming community, or based on criteria set forth by a parent with regard to homework, or based on a tracked number of interactions with others in a social circle within a computing community (such interactions need not be online, and need only be capable of being tracked), certain actions or gifts may be made available to or for use with a subject widgetized avatar. For example, three members of a social community may decide to form an avatar rock band, whereby, the more those three members communicate via email, instant message, SMS text, or the like, over a week, the better each member's avatar will play in a weekend “jam session.” Likewise, if an avatar corresponds to a person who makes a certain number of music purchases in a week, or a month, or in any predetermined time frame, the correspondent avatar may be enabled to dance with a certain popular musical artist, or dance as a certain popular musical artist in front of a concert crowd, for example. Other examples include, without limitation, allowing an avatar to play a sport, such as soccer, drive a car, such as a Ferrari, or accumulate points toward advancement in a game, or towards making purchases online.
[0029] Further, the present invention may allow for association of particular levels of expertise with particular areas of interest as related to the avatar trading card. As such, the user associated with the subject avatar may take a rating of that user's expertise in certain areas from computing community to computing community. Thus, searches may be made available in one or more computing communities for persons having desired levels of expertise in certain areas. The user may thus accumulate expertise points in multiple computing communities at the same time, wherein such points may be associated with that user's transferable widgetized avatar, whereby a user's expertise may rise based on accumulated expertise points. Additionally and alternatively, a user's expertise in a certain area may increase based on feedback from other users in one or more computing communities in relation to the subject users expertise in a particular area, or a user's expertise may increase based on an assignment of expertise levels by one or more of the computing communities, or a user's expertise level may rise based on advice offered, amount of advice offered, or purchase of expertise or advice from that user in or more on-line computing communities. Thus, a search by a party in need, such as a key word search, for an expert in a particular area may return not a user advertising to be an expert in a particular area, but instead may return a user adjudged to be an expert in a particular area by parties other than that user him or himself. Of course, in accordance with the present invention, such expertise levels may be associated with the avatar or avatar trading card, and as such may then subsequently be transferred to other computing communities.
[0030] Thus, the avatar of the present invention enables a user to create a portable, fully virtual, “person” for association with that user and carrying the characteristics of that user, including a personal profile and identification card that can be used in combination with any web page, web top or desk top and any computing community, transaction or social networking situation. Thereby, the avatar of the present invention allows users to connect with other users and share ideas, content, expertise, and applications. Further, the avatar of the present invention thus assists in viral growth by offering users of certain or multiple computing communities an avatar that keeps all personal profile information in one transportable place. Additionally, the avatars of the present invention may provide a foundation for a recommendation and expertise engine employing an algorithm that may suggest content or an expert based on a user's community, popularity, known expertise, clicks, interests, searches, or the like.
[0031] Thus, the avatar of the present invention may include one or more of the user profile, physicality of avatar, user personal characteristics, user interests, user links, user photos, videos, or audio, user friends, user sayings, jokes, or the like, user notes, connections or message postings, and user clothing, accessories, activities and general style. As used herein, the computing communities and transactions to which the avatar of the present invention may be transferred include all computing communities, including telecommunications communities such as those accessible from cellular telephones, televisions, and the like. As such, those skilled in the art will appreciate the all aspects of the avatar of the present invention, including creation and use, may be employed in any environment, including any mobile computing environment.
[0032] Although the invention has been described and pictured in an exemplary form with a certain degree of particularity, it is understood that the present disclosure of the exemplary form has been made by way of example, and that numerous changes in the details of construction and combination and arrangement of parts and steps may be made without departing from the spirit and scope of the invention. | A widgetized avatar and a method and system of creating and using same is disclosed. The avatar includes computing code that provides for addition of the avatar as non-static content to at least two unique at least partially static web pages, and secondary computing code resident within the computing code, wherein the secondary computing code provides for association with at least one other portion of the computing code of ones selected from a plurality of physical characteristics, a plurality of personal information, and a plurality of actions. | 6 |
PRIORITY CLAIM
[0001] The present application claims the priority benefit of U.S. provisional patent application No. 62/121,010 filed Feb. 26, 2015 and entitled “Vertically Aligned Metal Nanowire Arrays and Composites for Thermal Management Applications,” the disclosure of which is incorporated herein by reference.
CROSS-REFERENCE TO RELATED APPLICATION
[0002] This application contains subject matter that is related to the subject matter of the following applications, which are assigned to the same assignee as this application. The below-listed U.S. patent application is hereby incorporated herein by reference in its entirety:
[0000] “THERMAL INTERFACE MATERIALS USING METAL NANOWIRE ARRAYS AND SACRIFICIAL TEMPLATES,” by Barako, Starkovich, Silverman, Tice, Goodson, Coyan, and Peng, filed on ______, U.S. Ser. No. ______.
SUMMARY
[0003] A thermally-conductive and mechanically-robust bonding method for attaching a metal nanowire (MNW) array to an adjacent surface includes the steps of: removing a template membrane from the MNW; infiltrating the MNW with a bonding material; placing the bonding material on the adjacent surface; bringing an adjacent surface into contact with a top surface of the MNW while the bonding material is bondable; and allowing the bonding material to form a solid bond between the MNW and the adjacent surface.
[0004] A thermally-conductive and mechanically-robust bonding method for attaching a metal nanowire (MNW) array to an adjacent surface includes the steps of: choosing a bonding material based on a desired bonding process; and without removing the MNW from a template membrane to which the MNW is connected, depositing the bonding material onto a tips of the MNWs.
[0005] A metal nanowire (MNW) array includes: a vertically-aligned metal nanowire (MNW) array comprising a plurality of nanowires that grow upward from a seed layer deposited onto a template membrane, the template membrane being removed after MNW growth.
[0006] A metal nanowire (MNW) array includes a metal nanowire (MNW) array attached at the MNW tips to an adjacent surface by mushroom-like caps of thermally-conductive and mechanically-robust bonding material.
[0007] A metal nanowire (MNW) array includes a metal nanowire (MNW) array attached at the MNW tips to a continuous overplating layer of bonding material covers the template membrane.
DESCRIPTION OF THE DRAWINGS
[0008] The accompanying drawings provide visual representations which will be used to more fully describe various representative embodiments and can be used by those skilled in the art to better understand the representative embodiments disclosed herein and their inherent advantages. In these drawings, like reference numerals identify corresponding elements.
[0009] FIGS. 1A-1C is a set of three drawings showing a thermally-conductive and mechanically-robust bonding method for attaching a metal nanowire (MNW) array to an adjacent surface.
[0010] FIG. 2 is a drawing showing a thermally-conductive and mechanically-robust bonding method for attaching a metal nanowire (MNW) array to an adjacent surface.
[0011] FIG. 3 is a flowchart of a thermally-conductive and mechanically-robust bonding method for attaching a metal nanowire (MNW) array to an adjacent surface.
[0012] FIG. 4 is a flowchart of a thermally-conductive and mechanically-robust bonding method for attaching a metal nanowire (MNW) array to an adjacent surface.
DETAILED DESCRIPTION
[0013] While the present invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail one or more specific embodiments, with the understanding that the present disclosure is to be considered as exemplary of the principles of the invention and not intended to limit the invention to the specific embodiments shown and described.
[0014] A thermally-conductive and mechanically-robust bonding procedure is provided to attach a metal nanowire (MNW) array to two adjacent surfaces.
[0015] A thin metallic bonding layer can be used to anchor the individual MNWs to the adjacent surface without compromising the mechanical properties of the MNW. For example, a thickness of the metallic bonding layer is less than approximately 20% of one or more of the length of the MNW array and the height of the MNW array.
[0016] According to embodiments of the invention, metallically-bonded MNW MNWs may be implemented by infiltrating an interstitial volume of the MNW array with a bonding material and using adhesion of the bonding material to the adjacent surfaces as a method of attachment.
[0017] Alternatively, the tip of each MNW can be metallically bonded to an adjacent surface using a process that in parallel bonds all of the MNWs in the array. For example, while the MNWs are still in the membrane, a post MNW growth electrodeposition step can be used to deposit mushroom-like caps of bonding metal or alloy material onto the tips of the MNWs. The bonding cap can comprise one or more of a fusible metal and an alloy similar to a solder, a brazing agent or a diffusion bonding metal. An additional bonding layer is added at the top of the MNW.
[0018] If the MNWs are not grown to substantially extend to the full thickness of the membrane, then a bonding material can be deposited at the tip of the MNW to form a compound, segmented MNW. The segmented MNW is principally comprised of the conductive material while only a short section, less than 20% of the total MNW length located at the tip of the MNW is composed of the bonding material. If a slightly thicker bonding layer is desired, the electrodeposition of the bonding material can be continued until a continuous overplating layer of bonding material substantially covers the surface of one or more of the membrane and the MNW array. For example, the conductive material comprises one or more of copper and silver.
[0019] The bonding material is chosen based on the desired bonding process used. For example, one or more of a eutectic metal and a solder can be used for phase change bonding, where heating is applied to melt and adhere the molten bonding layer to the adjacent surface. Alternatively, the bonding material can be one or more of tin and gold and can be bonded using thermocompressive bonding. Alternatively, the bonding material comprises a polymer material. Other types of metallic bonding include brazing and welding, which can also be used to attach a bonding material at the MNW tips to an adjacent material.
[0020] FIGS. 1A-1C is a set of three drawings showing a thermally-conductive and mechanically-robust bonding method for attaching a metal nanowire (MNW) array to an adjacent surface. The legend indicates the various components.
[0021] In FIG. 1A , following deposition and growth of the MNWs, the template membrane used in generating the MNWs is removed.
[0022] In FIG. 1B , the MNW array is then infiltrated with one or more of a fusible metal, an alloy, and a polymer resin, creating bondable material. For example, the bondable material comprises molten material. For example, the bondable material is wicked by capillary forces into an interstitial volume of the MNW array by capillary forces. Bonding material is then placed on an adjacent surface to the MNW.
[0023] In FIG. 1C , an adjacent surface is brought into contact with a top surface of the MNW while the bonding material is bondable, For example, the bondable material comprises molten material. The bonding material is allowed to form a solid bond between the MNW and the adjacent surface, This process compresses one or more of the bonding material and the MNW array against the adjacent surface.
[0024] An additional step (not pictured) may be performed of wetting the bonding material to the adjacent surface.
[0025] FIG. 2 is a drawing showing a thermally-conductive and mechanically-robust bonding method for attaching a metal nanowire (MNW) array to an adjacent surface. The tips of an MNW array are bonded to an adjacent surface.
[0026] In step 210 , an MNW array is synthesized. The MNW array is grown to be either subfilled, where the length of the MNWs is less than the membrane thickness, as shown in step 215 , or filled to the top of the membrane such that the tips of the MNWs are even with the top surface of the membrane, as shown in step 220 . In either case, the membrane is left in place around the MNWs.
[0027] In step 225 , a bonding layer is deposited onto the tips of the MNWs. This bonding layer can take one of three different forms. As shown in step 230 , if the MNW array is subfilled, a small amount of bonding material can be deposited directly onto the tip of each individual MNW, forming a short MNW segment of bonding material.
[0028] As shown in step 235 , if the MNW array is filled to the membrane thickness, a small amount of bonding material can be deposited onto the tip of each individual MNW, forming a small mushroom-cap of bonding material above each individual MNW.
[0029] As shown in step 240 , if the MNW array is filled to the membrane thickness, a large amount of bonding material can be deposited onto the surface of the array and membrane to form a continuous film of bonding material.
[0030] In step 250 , the MNWs are bonded and the template membrane is removed.
[0031] In step 255 , the template membrane is removed from the previously subfilled MNW array, and then in step 260 , the MNW array is bonded to the adjacent substrate.
[0032] In step 265 , for the embodiments with bonding layer caps or with bonding layer overplating, the MNW array is first bonded to the adjacent substrate. The most common types of metallic bonding are solder/eutectic bonding, where the bonding material comprises one or more of a solder and a eutectic and where bonding is performed under heating and optional compression, and thermocompressive bonding, where the bonding material comprises one or more of tin and gold, and wherein bonding is performed under heating and compression.
[0033] In step 270 , the template membrane is removed from the MNW array, FIG. 3 is a flowchart of a thermally-conductive and mechanically-robust bonding method 300 for attaching a metal nanowire (MNW) array to an adjacent surface.
[0034] In step 310 , a template membrane is removed from the metal nanowire (MNW) array. Block 310 then transfers control to block 320 .
[0035] In step 320 a bonding material is placed on an adjacent surface to the MNW. Block 320 then transfers control to block 330 .
[0036] In step 330 the MNW is infiltrated with a bonding material. For example, the step of infiltrating comprises heating the bonding material so that it becomes one or more of softened and molten. For example, the step of infiltrating comprises chemically treating a composite material so as to create a bonding material. Block 330 then transfers control to block 340 .
[0037] In step 340 , a surface adjacent to the MNW is brought into contact with a top surface of the MNW while the bonding material is bondable. Block 340 then transfers control to block 350 .
[0038] In block 350 , the bonding material is allowed to form a solid bond between the MNW and the adjacent surface. Block 350 then terminates the process.
[0039] FIG. 4 is a flowchart of a thermally-conductive and mechanically-robust bonding method 400 for attaching a metal nanowire (MNW) array to an adjacent surface.
[0040] In step 410 , a bonding material is chosen based on a desired bonding process. Block 410 then transfers control to block 420 .
[0041] In step 420 , without removing a metal nanowire (MNW) array from a template membrane, the bonding material is deposited onto a tip of the MNW. Block 420 then terminates the process.
[0042] Advantages of the invention include high thermal conductivity outside of the interfaces and formation of a cohesive joint between the two components. Embodiments of the invention minimize the thermal resistance between the MNW surface and the adjacent surface and provide long-lifetime adhesion that preserves its integrity under temperature gradients and thermal cycling. Fusible metal MNWs are used in applications where the mechanical stresses are comparatively low or for applications where the minimization of device temperature rise (or equivalently for high-heat flux devices) is the priority of the thermal design. For example, the mechanical stresses are less than approximately 20 megapascals (20 MPa).
[0043] Fusible metals undergo a phase change during bonding and can provide direct adhesion to adjacent surfaces. However, the resulting MNW must be comparatively thick since the bonding metal is stiff and mismatch in the coefficients of thermal expansion can cause the interface to fail. In vertically-aligned MNWs, the MNWs provide both high thermal conductivity (greater than 20 watts per meter-kelvin [W/m-K]) and mechanical compliance. For example, the mechanical compliance is between approximately 10 megapascals (MPa) and approximately 100 MPa. For example, the mechanical compliance is between approximately 10 MPa and 1,000 MPa. The MNWs themselves provide the mechanical flexibility. The bond serves primarily to transfer heat between the surface and the MNW array and to maintain mechanical integrity of the interface.
[0044] While the above representative embodiments have been described with certain components in exemplary configurations, it will be understood by one of ordinary skill in the art that other representative embodiments can be implemented using different configurations and/or different components. For example, it will be understood by one of ordinary skill in the art that the time horizon can be adapted in numerous ways while remaining within the invention.
[0045] The representative embodiments and disclosed subject matter, which have been described in detail herein, have been presented by way of example and illustration and not by way of limitation. It will be understood by those skilled in the art that various changes may be made in the form and details of the described embodiments resulting in equivalent embodiments that remain within the scope of the invention. It is intended, therefore, that the subject matter in the above description shall be interpreted as illustrative and shall not be interpreted in a limiting sense. | A thermally-conductive and mechanically-robust bonding method for attaching a metal nanowire (MNW) array to an adjacent surface includes the steps of: removing a template membrane from the MNW; infiltrating the MNW with a bonding material: placing the bonding material on the adjacent surface; bringing an adjacent surface into contact with a top surface of the MNW while the bonding material is bondable; and allowing the bonding material to cool and form a solid bond between the MNW and the adjacent surface. A thermally-conductive and mechanically-robust bonding method for attaching a metal nanowire (MNW) array to an adjacent surface includes the steps of: choosing a bonding material based on a desired bonding process; and without removing the MNW from a template membrane that fills an interstitial volume of the MNW, depositing the bonding material onto a tip of the MNW. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. provisional application No. 60/643,169, filed 13 Jan. 2005, hereby incorporated herein by reference, entitled “Hybrid Joint,” joint inventors Roger M. Crane, Robert DeNale, Harry E. Prince, and Timothy L. Dapp.
STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without payment of any royalties thereon or therefor.
BACKGROUND OF THE INVENTION
The present invention relates to composites and composite materials, more particularly to methods and configurations for joining composite structures to other composite structures or to non-composite structures.
Many structural applications require the joining of composites to composites, or composites to metals. These kinds of joints are often technologically challenging. Conventional approaches to joining composites with other composites or with metals include mechanical fastening (e.g., bolting), adhesive bonding, co-curing, and secondary bonding. A common design for mechanical fastening is a lap joint, which is typically formed by overlapping two panels, then match-drilling holes in the two panels, and then inserting bolts to fasten together the two panels. A common design for adhesive bonding is a scarf joint, which is typically formed by matching the respective tapered edges of two panels, and applying an adhesive material so as to achieve a uniform thickness joint having an adhesive bond line between the two matched tapered edges. Scarf joints also lend themselves to co-curing or secondary bonding, either of which obviates the need for adhesive bonding. According to typical co-curing technique, a joint involving two uncured panels is laid up and cured in one step. According to typical secondary bonding technique, an uncured panel is laid onto a previously cured panel and attached thereto via a second cure.
The aerospace industry has considerable experience with fabrication of composite-to-metal joints. In aerospace structure technology, mechanical fastening and adhesive bonding are the two most popular approaches to joining composite materials with metal materials. Prevalent in aerospace applications is a “bolted-bonded” configuration, in which mechanical fastening and adhesive bonding are combined to create redundant load paths in a structure. Bolted-bonded configurations are also seen in marine applications involving the joining of composite components to metallic structures; however, adhesives are susceptible to degradation in aqueous environments. An adhesive bond entails not one but two interfaces that are prone to disbonding, namely, the respective interfaces between the adhesive layer and the two adherends. Therefore, regardless of whether it is used alone or in combination with mechanical fastening, adhesive bonding is viewed much less favorably in the marine realm than it is in the aerospace realm. Moreover, for many marine structures, the sizes and shapes of the structural sub-assemblies prohibit the use of either co-curing or secondary bonding as a joining technique. Accordingly, mechanical fastening (e.g., bolted joints) has been widespread in the marine industry as an exclusive joining technique.
Mechanical fastening can be utilized to great benefit but has several drawbacks. Since composites tend to be sensitive to damage under high bearing pressures, a lap joint must be carefully designed in order to carry the intended loads without accumulating damage in the vicinity of the bolt-holes in the composite. Commentators have cautioned that maintaining close fit-up between the holes and the bolts, and between the members being joined, is important for maximizing fatigue performance. Some composites also exhibit low temperature creep that leads to loss of preload in the bolts and accelerates damage, a proclivity that may necessitate regular maintenance of the bolted joints to maintain preload. The advantageousness of composites in terms of weight savings may be vitiated by bolted joints because of the weight of the bolts, and because the composite panel thickness is often increased in the vicinities of the bolted joints to decrease the bearing stresses in the composite.
Bolted lap joints may be impractical for outer hull applications where hydrodynamics (or aerodynamics) is a consideration, because a simple lap joint entails at least one “step” (where the lapped panels overlap) on the hull structure's surface. Although bolted flange joints can be used for attachment of hull sections, these are significantly heavier than bolted lap joints. A tapered lap joint configuration (in which the panels of a lap joint are tapered on the edges) can be adopted so as to ameliorate the negative effects of the overlaps on the hull structure's hydrodynamic (or aerodynamic) characteristics. As distinguished from a tapered lap joint, the above-mentioned scarf joint matches (interfaces) the tapered edges of panels so as to achieve a uniform thickness joint; typically, adhesive bonding is implemented where the respective tapered edge surfaces of the panels are matched up. A scarf joint, if properly designed, can achieve a uniform shear stress in the bond line, thus representing a highly efficient joint. Theoretically, at least, the potential efficiency of an adhesive joint is superior to that of a mechanical joint, since an adhesive joint is theoretically capable of achieving one hundred percent of the laminate strength. Nevertheless, as previously noted herein, marine use of adhesive bonding can be problematical due to the tendency of adhesive materials to degrade in aqueous environments.
SUMMARY OF THE INVENTION
In view of the foregoing, it is an object of the present invention to provide a improved methodology for joining a nonmetallic composite (e.g., fiber-reinforced matrix) structure and a metallic non-composite (e.g., monolithic) structure.
The United States Navy utilizes various nonmetallic composite structures, typically lightweight, on the decks of naval ships. Heretofore the most commonly practiced approach to attaching a composite structure to a naval vessel surface has combined extensive mechanical bolting with adhesive bonding. Some combined mechanical-adhesive approaches, for instance, have involving lap joint attachment between overlapping panels. The present invention succeeds in effecting attachment of composite structures to a metallic substrate, such as the steel deck of a marine vessel, in such a way as to avoid both mechanical fastening (and its associated shortcomings, including deterioration of the bolting through-holes in the composite, loss of preload in the bolts, excessive weight of the bolts, compromise of hydrodynamic or aerodynamic properties, etc.) and adhesive bonding (and its associated shortcomings, including susceptibility to damage caused by an aqueous environment, susceptibility to disbonding, etc.). The present invention's novel attachment methodology is lighter, less extensive, less cumbersome, less costly, and less vulnerable to environmental and other deleterious influences than are the currently known attachment methodologies involving combination of bolting and adhering.
Noteworthy is a family of high strength steel fiber reinforcement products known as HARDWIRE®, commercially available, manufactured by Hardwire LLC, 1000 Quinn Avenue, Pocomoke City Md., 21851, website http://www.hardwirellc.com. Especially useful for inventive practice are the HARDWIRE® unidirectional high strength steel wire (fiber) tapes, such as those available in twelve-inch widths. Tests performed at the Naval Surface Warfare Center, Carderock Division (NSWCCD) have demonstrated HARDWIRE® to be easily processed and to have significant mechanical properties. NSWCCD investigators have shown that steel fiber reinforcement composite panels can be manufactured, using HARDWIRE® unidirectional steel fiber tapes, via a vacuum assisted resin transfer molding (VARTM) process. Available online beginning on or about 1 Mar. 2004 at the Hardwire LLC website, http://www.hardwirellc.com, is the following unpublished U.S. Navy technical report, incorporated herein by reference, which examines some material properties of certain specimens made using HARDWIRE®: Robert Matteson and Roger M. Crane, “Flexural Testing of Steel Wire Composite Beams Made with Hardwire™ Unidirectional Tape,” NSWCCD-65-TR-2003/48, Naval Surface Warfare Center, Carderock Division, face-dated November 2003 but never published. In providing its unique composite-to-metal joint technology, the present invention brings to bear resin transfer molding (RTM) technology such as in a form of VARTM processing that is analogous to previously demonstrated VARTM processing of HARDWIRE® unidirectional steel fiber tapes. HARDWIRE® represents one product line that can be utilized propitiously in practicing the present invention; nevertheless, the ordinarily skilled artisan who reads the instant disclosure will appreciate that multifarious metallic fiber reinforcement articles other than HARDWIRE® articles lend themselves to inventive practice.
In accordance with typical embodiments of the present invention, a method is provided for effecting attachment between a first structure and a second structure. The first structure includes nonmetallic fibrous material. The second structure includes metallic material. The method comprises: (a) effecting a co-cure joint between the first structure and a first portion of an intermediate structure; and, (b) effecting a weld joint between the second structure and a second portion of the intermediate structure. The intermediate structure includes metallic fibrous material. According to many inventive embodiments, the effecting of a co-cure joint between the first structure and the first portion of the intermediate structure includes: (i) adjoining the first structure and the first portion of the intermediate structure; (ii) impregnating with resin the first structure and the first portion of the intermediate structure; and, (iii) curing the first structure and the first portion of the intermediate structure. According to many inventive embodiments, the effecting of a weld joint between the second structure and the second portion of the intermediate structure includes: (i) welding two metallic plates on opposite sides of the second portion of the intermediate structure; and, (ii) welding the second structure and the combination including the two metallic plates and the second portion of the intermediate structure.
Featured by typical embodiments of the present invention is the implementation of a metallic fibrous “preform” material (such as embodied by preform panels made from HARDWIRE® unidirectional steel fiber tapes) as a “transitional” material for coupling a nonmetallic fibrous “preform” material (such as embodied by preform panels made from conventional E-glass-woven roving or another glass fabric material) with a metallic nonfibrous material (typically a primary structural, monolithic material such as embodied by the metallic deck, or portion thereof, of a ship or other marine vessel). Two different joints—viz., a co-cure joint and a weld joint—are created at different locations (e.g., on opposite sides) of the metallic fibrous material so as to “transition” the nonmetallic fibrous material into the metallic nonfibrous material. The metallic fibrous material represents the “transitional” structure. The co-cure joint is created between the nonmetallic fibrous material and a first part of the metallic fibrous material. The weld joint is created between the metallic nonfibrous material and a second (separate) part of the metallic fibrous material. The fibrous structural characteristic, shared by the nonmetallic fibrous material and the metallic fibrous material, fosters their co-cure joining. The metallic structural characteristic, shared by the nonmetallic fibrous material and the metallic nonfibrous material, fosters their weld joining. The terms “metal” and “metallic,” as used herein, refer in the broadest sense to any material including metal, such as an elemental metal material or an alloy material.
According to typical inventive practice, plural nonmetallic fiber reinforcement preform panels are stacked so as to overlap one another; similarly, plural metallic fiber reinforcement preform panels are stacked so as to overlap one other. Since, generally, the metallic fiber reinforcement preform panels should be appropriately dimensioned for participation in a co-cure bond in one section thereof and a weld joint in another section thereof, inventive practice will sometimes prefer to provide such panels that are elongated. The interlocking junction between the two fibrous stacks along their staggered edges describes a stepped (stepped lap) configuration. The two adjoining fibrous stacks (one nonmetallic, the other metallic) of preform material are “co-impregnated” (i.e., jointly impregnated—e.g., infiltrated or infused—in a single step) with a single resin system (e.g., a vinyl ester resin)—so that an exposed section of the metallic fibrous (e.g., HARDWIRE® steel wire) stack is not impregnated with resin. The adjoining, impregnated combination of panel preform stacks is “co-cured” (i.e., jointly cured, in a single step), this co-curing excluding the uninfiltrated metallic fibrous section. The co-cured combination of nonmetallic and metallic fibrous material represents a kind of “hybrid” fiber-reinforced matrix material system, in which a single resinous matrix system is used to infiltrate at least two different types of fiber reinforcement.
The uninfiltrated, uncured metallic fibrous section is capable of being welded to a separate metallic structure, thereby uniting the separate metallic structure (located at one end of the uninfiltrated, uncured metallic fibrous section) with the hybrid fiber-reinforced matrix material system (located at the opposite end of the uninfiltrated, uncured metallic fibrous section); in effect, this uniting accomplishes the attachment of the nonmetallic fibrous material (now infiltrated with resin) with respect to the separate metallic structure. According to frequent inventive practice, auxiliary metallic structure is welded to at least a portion of the uninfiltrated, uncured metallic fibrous section in order to facilitate “weldability” to another metallic structure (especially a larger, more “structural” body such as a steel ship deck). For instance, the uninfiltrated, uncured metallic fibrous section (e.g., a planar section of a stacked panel assembly) is welded on opposite sides to two metallic (e.g., steel) plates, thereby forming a sandwich configuration of uninfiltrated, uncured metallic fibrous material layer situated between two metallic plate layers. As an alternative approach, according to some inventive embodiments at least a portion of the uninfiltrated, uncured metallic fibrous section is welded on one side to one metallic (e.g., steel) baseplate. Thus enhanced by one or more metallic plates, the uninfiltrated, uncured metallic fibrous section (or a portion thereof) is especially capable of being attached by means of welding to a large metallic structure such as a steel ship deck.
The following paper, incorporated herein by reference, examines (using numerical method such as finite element analysis) stresses and strains associated with certain co-cured stepped joint configurations representative of inventive practice, wherein the two adherends of the co-cure joint are fiber-reinforced laminates of unequal stiffness, and wherein a continuous matrix surrounds the fibers on both sides of the co-cure joint: Stephen M. Graham, “Stress Analysis of a Co-Cured Innovative Hybrid Joint for Marine Composites,” SAMPE (Society for the Advancement of Material and Process Engineering) 2004, 16-20 May 2004, Long Beach, Calif. The stiffness mismatch between the fibrous non-metallic material and the fibrous metallic material can pose a problem when these materials are co-cured in accordance with the present invention. This mismatch can lead to strain localization, which can cause matrix or fiber damage. As this area is loaded over time, the damage can accumulate and cause eventual failure. As disclosed by Graham, early analysis of the present invention's hybrid joint has shown that it can be designed to minimize the detrimental aspects of the stiffness mismatch. The following paper, incorporated herein by reference, examines tensile strengths associated with certain co-cured stepped joint configurations representative of inventive practice: Stephen M. Graham, Tad Robbins, and Roger M. Crane, “Influence of Joint Geometry on Tensile Strength of a Co-Cured Symmetric Stepped-Lap Joint,” SAMPE (Society for the Advancement of Material and Process Engineering) 2005, 1-5 May 2005, Long Beach, Calif.
A typical co-cure joint in accordance with the present invention (in which a non-metal fiber material and a metal fiber material are joined together) is stronger than a co-cure joint in which two non-metal fiber materials are joined together, due to the markedly greater stiffness afforded by a metal fiber material as compared with a non-metal fiber material. This superiority in joint strength is attributable at least in part to the bending of the combined structure in the direction of the metal fiber (i.e., stiffer) material, which thus carries more of the load. Furthermore, the inventive co-cure joint will tend to be stronger than an adhesive joint, since the inventive co-cure joint involves no adhesive but rather involves a uniform matrix material, the loading therefore being more uniform with fewer stress concentrations. Through proper tailoring of the two different fiber systems (one metallic, one nonmetallic) that are joined via the present invention's co-cure joint, the present invention's hybrid composite configuration can be tailored to have a more efficient load transfer from the metal composite into the conventional composite with even further reduced stress concentrations. In inventive practice involving some marine deck applications, for instance, the present invention's metal fiber intermediary structure, in acting as a “transitional” vehicle between a composite and a steel deck, serves to reduce the stiffness mismatch between the composite and the steel deck. Since there is no fastening (e.g., bolting) or machining required, the cost and weight of the present invention's co-cure joint are significantly less than the cost and weight of a mechanical joint. The present invention's provision for welding to a metallic structure (e.g., steel substructure) will permit Page of conventional shipyard skills and practices to be used, further reducing the cost of the joining process. The present invention's obviation of fasteners (e.g., bolts) will provide reduced life cycle costs, since there is no need to check and re-torque the fasteners (e.g., bolts). Inventive practice can feature the hybridization, within individual panels, of high stiffness fiber along with conventional glass fiber, wherein the two fiber types are embedded together in a matrix such as a vinyl ester. These hybridized panel forms can afford greater stiffness and lesser volume as compared with conventional composite cored construction.
Other objects, advantages and features of the present invention will become apparent from the following detailed description of the present invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described, by way of example, with reference to the accompanying drawings, wherein:
FIG. 1 is a perspective view of two nonmetallic fibrous perform panels and two metallic fibrous preform panels of equal widths and thicknesses and varying lengths.
FIG. 2 is an elevation view of the contiguous arrangement of the four preform panels shown in FIG. 1 so as to form a stepped interface in accordance with the present invention.
FIG. 3 is an elevation view, similar to the view of FIG. 2 , illustrating the co-impregnation and co-curing, in accordance with the present invention, of the two nonmetallic fibrous preform panels and portions of the two metallic fibrous preform panels.
FIG. 4 is an elevation view, similar to the views of FIG. 2 and FIG. 3 , of an inventive integral hybrid panel describing a co-cure region (including the co-impregnated and co-cured combination of the two nonmetallic fibrous preform panels and the respective portions of the two metallic fibrous preform panels) and a weld region (including an unimpregnated, uncured portion of the respective portions of the two metallic fibrous perform panels).
FIG. 5 is a plan view of the inventive integral hybrid panel shown in FIG. 4 .
FIG. 6 is the view of the inventive integral hybrid panel shown in FIG. 4 , illustrating the sandwich-welding of two metallic plates. The metallic plates shown in FIG. 6 are coextensive with the co-cure region.
FIG. 6A is the view, similar to the view of FIG. 6 , of the inventive integral hybrid panel shown in FIG. 4 , illustrating the sandwich-welding of two metallic plates that are shorter than those shown in FIG. 6 .
FIG. 7 is the view of the inventive integral hybrid panel shown in FIG. 6 , wherein the two metallic plates are shown welded on opposite sides of the bare (unimpregnated, uncured) metallic fibrous material in the co-cure region. FIG. 7 illustrates the welding of the sandwich-welded co-cure region to a metallic structure such as a steel ship deck. The metallic plates shown in FIG. 7 are coextensive (i.e., cover all of) with the co-cure region.
FIG. 7A is the view of the inventive integral hybrid panel shown in FIG. 6A , wherein the two metallic plates are shown welded on opposite sides of the bare (unimpregnated, uncured) metallic fibrous material in the co-cure region. FIG. 7A illustrates the welding of the sandwich-welded co-cure region to a metallic structure such as a steel ship deck. The metallic plates shown in FIG. 7A are less than coextensive with (i.e., cover part of) the co-cure region.
FIG. 8 is the view of the inventive integral hybrid panel and the metallic structure shown in FIG. 7 , wherein the inventive integral hybrid panel and the metallic structure are shown welded together.
FIG. 8A is the view of the inventive integral panel and the metallic structure shown in FIG. 7A , wherein the inventive integral hybrid panel and the metallic structure are shown welded together.
FIG. 9 , FIG. 10 and FIG. 11 are three examples among the multifarious stepped interface configurations that can be inventively practiced in the co-cure region of an inventive integral hybrid panel. The stepped interface configuration shown in FIG. 9 , FIG. 10 and FIG. 11 are but three alternatives to the two-step interface, uniform thickness configuration shown in FIG. 4 through FIG. 8A , indicated by encirclement in FIG. 6 and FIG. A).
FIG. 12 , FIG. 13 and FIG. 14 are three examples among the multifarious embodiments of an overall inventive structure representing the association of an inventive integral hybrid panel with a metallic structure such as a steel ship deck.
FIG. 15 illustrates inventive practice according to which plural inventive integral hybrid panels are connected end-to-end via welding of respective bare (i.e., unimpregnated and uncured) metallic fibrous sections. Two of the shown inventive integral hybrid panels are “multi-sectioned” in the sense of having plural nonmetallic fibrous sections that are impregnated and cured, plural metallic fibrous sections that are impregnated and cured, and at least one metallic fibrous section that is bare.
DETAILED DESCRIPTION OF THE INVENTION
Reference is now made to FIG. 1 , which depicts two nonmetallic fibrous preform panels 20 (viz., 20 a and 20 b ) and two metallic fibrous preform panels 30 (viz., 30 a and 30 b ). The nonmetallic fiber panel preforms 20 are composed, for example, of E-glass woven roving. The metallic fiber panel preforms 30 are composed, for example, of HARDWIRE® unidirectional high strength steel wires. Panels 20 and 30 can be either single-ply or multi-ply. All four panel preforms 20 and 30 are characterized by the same width w and thickness t, but vary in length l.
With reference to FIG. 2 , nonmetallic fiber panel performs 20 a and 20 b are stacked so as to be even at their lefthand edges and to be overlapping at their righthand edges. Similarly, metallic fiber panel preforms 30 a and 30 b are stacked so as to be even at their righthand edges and to be overlapping at their lefthand edges. The pair of overlapping nonmetallic fiber panel preforms 20 a and 20 b (at their staggered righthand edges) are adjoined with the pair of overlapping metallic fiber panel preforms 30 a and 30 b (at their staggered lefthand edges). The adjunction between the two overlapping nonmetallic fiber panel preforms 20 a and 20 b and the two overlapping metallic fiber panel preforms 30 a and 30 b describes a stepped interface 40 , a two-step (double-step) configuration of uniform thickness. The term “stepped configuration” is used synonymously herein with the term “stepped lap configuration.” It can be considered that the two abutting, overlapping nonmetallic fiber panel preforms 20 a and 20 b together form a combined nonmetallic fiber preform panel structure 200 , and that the two abutting, overlapping metallic fiber panel preforms 30 together form a combined metallic fiber preform panel structure 300 ; combined nonmetallic fiber preform panel structure 200 and combined metallic fiber preform panel structure 300 together form an integral preform panel structure 100 . Stepped interface 40 is thus established between the combined nonmetallic fiber preform panel structure 200 and the combined metallic fiber preform panel structure 300 .
Both the combined nonmetallic fiber preform panel structure 200 and the combined metallic fiber preform panel structure 300 are composed essentially of dry fiber preform materials. Nonmetallic fiber preform panel structure 200 and portion 301 (which consists of abutting respective portions of metallic fiber panel preform 30 a and metallic fiber panel preform 30 b ) of metallic fiber preform panel structure 300 are co-impregnated (e.g., co-infused) in a single impregnation step with a single resin system and are then co-cured (for instance, using VARTM or another conventional RTM technique), resulting in a continuous resinous matrix 60 encompassing two distinct fiber forms, namely, the nonmetallic fibers of preform panel structure 200 and the metallic fibers of portion 301 of preform panel structure 300 . No resin 60 is permitted to flow into portion 302 (which consists of abutting respective portions of metallic fiber panel preform 30 a and metallic fiber panel preform 30 b ) of metallic fiber preform panel structure 300 , which defines a weld region W. RTM (e.g., VARTM) apparatus 50 is diagrammatically shown as circumscribing nonmetallic preform panel structure 200 and portion 301 of preform panel structure 300 , the combination of which defines a co-cure region C. The two overlapping nonmetallic fiber panel preforms 20 and the two overlapping metallic fiber panel preforms 30 are thus joined together via the impregnation; in particular, nonmetallic fiber preform panel structure 200 (formed by the two overlapping nonmetallic fiber panel preforms 20 a and 20 b ) and metallic fiber preform panel structure 300 (formed by the two overlapping nonmetallic fiber panel preforms 30 a and 30 b ) are joined together at stepped interface 40 via the impregnation of resin 60 and in the absence of any other bonding methodology such as involving adhesive material, mechanical fastening, or secondary bonding.
Referring to FIG. 4 and FIG. 5 , fabricated via the above-described co-cure process is an integral hybrid composite panel 1000 that includes a nonmetallic fiber-reinforced matrix section 2000 C, a metallic fiber-reinforced matrix section 3000 C, and a bare metallic fiber section 3000 W. Co-cure region C is commensurate with nonmetallic fiber-reinforced matrix section 2000 C in combination with metallic fiber-reinforced matrix section 3000 C (i.e., portion 301 ). Weld region W is commensurate with bare metallic fiber section 3000 W (i.e., portion 302 ). Via the impregnation and cure processing, the unimpregnated and uncured stepped interface 40 has become an impregnated and cured stepped interface 400 characterized by a co-cure joining of nonmetallic fiber preform panel structure 200 and metallic fiber preform panel structure 300 .
Reference is now made to FIG. 6 , FIG. 7 , FIG. 8 , FIG. 6A , FIG. 7A and FIG. 8A . The bare metallic fibrous (e.g., HARDWIRE®) material is sandwiched between metallic (e.g., steel) plates and is then welded thereto to form a single metallic piece. This welded combination is then welded to the metallic substrate (e.g., steel deck). FIG. 6 , FIG. 7 and FIG. 8 illustrate a welding process involving two approximately congruent sandwich plates 70 that are each approximately coextensive with metallic fiber-reinforced matrix section 3000 C. FIG. 6A , FIG. 7A and FIG. 8A illustrate a welding process involving two sandwich plates 70 that are each significantly shorter than metallic fiber-reinforced matrix section 3000 C (roughly half the length of metallic fiber-reinforced matrix section 3000 C, as shown in FIG. 6A , FIG. 7A and FIG. 8A ). As shown in FIG. 6 , FIG. 7 and FIG. 8 , in the weld region W, two metallic (e.g., steel) weld plates 70 that are approximately coextensive with metallic fiber-reinforced matrix section 3000 C are welded onto opposite sides (faces) of metallic fiber-reinforced matrix section 3000 C, which includes no resin and consists only of bare steel wire material. The bare steel wire material of metallic fiber-reinforced matrix section 3000 C is sandwiched between the two plates 70 a and 70 b by means of known welding technique such as tungsten gas metal arc welding or friction stir welding, thereby forming, in weld region W, a single or unified metallic material that includes the two metallic sandwich plates 70 and the metallic fiber-reinforced matrix section 3000 C.
Subsequently, the welded combination of the two metallic sandwich plates 70 and the metallic fiber-reinforced matrix section 3000 C is welded to a metallic structure 99 (e.g., a steel marine deck) using known welding technique (e.g., tungsten gas metal arc welding or friction stir welding); hence, welded together in weld region W are the two metallic sandwich plates 70 , the metallic fiber-reinforced matrix section 3000 C, and at least a portion of the metallic structure 99 . Thus accomplished, in effect, is the attachment of a nonmetallic fiber-reinforced composite structure 2000 with respect to a metallic structure 99 in the absence of adhesive bonding or mechanical fastening. The procedure depicted in FIG. 6A , FIG. 7A and FIG. 8A sequence parallels the procedure depicted in FIG. 6 , FIG. 7 and FIG. 8 sequence, except that in the former drawing sequence the metallic sandwich plates are shown to cover only a portion of the metallic fiber-reinforced matrix section 3000 C, thus leaving an unwelded bare metallic fiber region U that lies adjacent to and between the co-cure region C and the weld region W. Furthermore, FIG. 7 and FIG. 8 depict weld attachment at a longitudinal end edge 89 in weld region W of the integral hybrid composite panel 1000 so that the integral hybrid composite panel 1000 is situated normal (perpendicular) with respect to the metallic structure 99 ; conversely, FIG. 7A and FIG. 8A depict weld attachment at an appropriately adapted longitudinal end edge 89 in weld region W of the integral hybrid composite panel 1000 so that the integral hybrid composite panel 1000 is situated oblique with respect to the metallic structure 99 . The oblique end edge 89 shown in FIG. 8A can be engineered either subsequent to (e.g., machined) or during the fabrication of the integral hybrid composite panel 1000 .
Stepped interface 400 shown in FIG. 4 and other figures represents a simple case of a two-step, uniform-thickness, interface 400 configuration. With reference to FIG. 9 through FIG. 11 , diverse interface 400 stepped configurations are possible in accordance with the present invention. FIG. 9 depicts stepped interface 400 ′, an asymmetrical five-step configuration. FIG. 10 depicts stepped interface 400 ″, a symmetrical five-step configuration. FIG. 11 depicts scarfed interface 400 ′″, an asymmetrical scarf joint-like interface that is tantamount to an asymmetrical stepped interface having numerous or infinite steps. The ordinarily skilled artisan who reads the instant disclosure will recognize the variety of possibilities for inventive practice with regard to the joint configuration at the co-cure interface between nonmetallic fibrous material and metallic fibrous material.
With reference to FIG. 12 through FIG. 14 , in each of these figures an inventive hybrid composite panel has two extreme weld regions W and a co-cure region C therebetween. In FIG. 12 and FIG. 13 , the co-cure region C (of inventive panel 1000 ′ in FIG. 12 and inventive panel 1000 ″ in FIG. 13 ) is characterized by lateral symmetry described by two height-wise asymmetrical step configurations 400 . The laterally symmetrical dual step joint pattern is inverted in FIG. 13 versus FIG. 12 . In FIG. 14 , the co-cure region C of inventive hybrid panel 1000 ′″ is characterized both by lateral symmetry and height-wise symmetry. Note that in FIG. 12 through FIG. 14 the weld to a metallic structure 99 is effected so that the bottom surface of bottom metallic plate 70 b abuts the top surface of metallic structure 99 . Such embodiments may obviate the need for welding a top metallic plate 70 a onto the bare metallic fibrous material of the inventive hybrid panel. FIGS. 12 through 14 are not intended to portray preferred inventive embodiments, but rather are intended to merely illustrate a few more of the multifarious configurational possibilities involving attachment of an inventive hybrid structure with respect to a metallic structure in accordance with the present invention.
Now referring to FIG. 15 , three different inventive hybrid panels—viz., panels 1000 a , 1000 b and 1000 c —are welded together, end to end, at their corresponding weld regions. Inventive panel 1000 a has weld region Wa; inventive panel 1000 b has weld regions Wb 1 and Wb 2 ; inventive panel 1000 c has weld region Wc. Weld region Wa of inventive panel 1000 a is welded to weld region Wb 1 of inventive panel 1000 b ; weld region Wc of inventive panel 1000 c is welded to weld region Wb 2 of inventive panel 1000 b . FIG. 15 is diagrammatically representative of inventive embodiments in which two or more inventive hybrid structures are welded together at their respective bare metallic fibrous material sections. The present invention thus provides, in addition to a unique composite-to-metal attachment methodology, a unique composite-to-composite attachment methodology. FIG. 15 is also illustrative of inventive practice in which an inventive hybrid panel includes, in addition to at least one unimpregnated and uncured metallic fiber section, plural impregnated and cured nonmetallic fiber sections and plural impregnated and cured metallic fiber sections, wherein unlike material sections are alternately arranged. Some inventive hybrid panel embodiments are thus characterized by a propitious mix of lesser stiffness fiber-reinforced composite (wherein the fibers are nonmetallic) along with greater stiffness fiber-reinforced composite (wherein the fibers are metallic). An inventive hybrid composite panel with such or similar inventive features can offer material and structural qualities in terms of both strength and lightness in weight.
The present invention, which is disclosed herein, is not to be limited by the embodiments described or illustrated herein, which are given by way of example and not of limitation. Other embodiments of the present invention will be apparent to those skilled in the art from a consideration of the instant disclosure or from practice of the present invention. Various omissions, modifications and changes to the principles disclosed herein may be made by one skilled in the art without departing from the true scope and spirit of the present invention, which is indicated by the following claims. | The present invention's composite-to-metal attachment methodology—bolt-free and adhesive-free—features the implementation of an intermediary structure containing metallic fibrous material. The intermediary structure couples a first adherend (which contains nonmetallic fibrous material) with a second adherend (which contains metallic nonfibrous material). The intermediary structure's fibrous attribute is availed of for effecting its co-cure attachment to the first adherend. The intermediary structure's metallic attribute is availed of for effecting its weld attachment to the second adherend. According to typical inventive practice, respective panels of the first adherend and the intermediary structure are arranged and connected so as to describe a stepped configuration at the interface between the first adherend and the intermediary structure. The first adherend and a first portion of the intermediary structure are co-impregnated with a uniform resinous system and are co-cured. A second portion of the intermediary structure is welded with respect to the second adherend. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of our copending application, U.S. Ser. No. 063,102, filed Aug. 2, 1979, now U.S. Pat. No. 4,298,393, and assigned to the same assignee as the present application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention pertains to methods and apparatus for the production of cement clinker.
2. The Prior Art
With the introduction of raw meal pre-heaters into the cement clinker burning process, rotary kilns which up to then had been long could be built shorter. With modern burning systems incorporating conventional cyclone pre-heaters, a ratio between the length of the rotary kiln to the inside rotary kiln diameter of approximately 15:1 through 17:1 has become general in practice. Efforts of the system manufacturers to further reduce the relative rotary kiln length have failed because of the safety requirements of the system users. Longer rotary kilns have tended to result in disruption-free operation, particularly with respect to interior cycles.
With the introduction of pre-calcination technology with secondary firings in the pre-heating system, a high degree of deacidification of the raw meal was achieved before entry into the rotary kiln. The advantages of lower heat introduction in the sintering zone of the rotary kiln, however, were only partially exploited. The kiln diameter was approximately reduced in relationship to the proportionate heat amounts supplied, on the one hand, to the pre-burner locations and, on the other hand, to the sintering zone of the rotary kiln. Until now, the standard ratio of kiln length to inside kiln diameter (15:1 through 17:1) mentioned above was approximately retained. As a result, specific rotary kiln lengths which were still large ensued, which resulted in high investment and operating costs. On the other hand, a reduction of the diameter of the rotary kiln, given the same throughput capacity and the same degree of oven charge, produced a shorter dwell period of the raw meal or, respectively, clinker in the rotary kiln. Therefore, until now, a further shortening of the rotary kiln was not considered.
The substances volatilizing in the rotary kiln often exhibit harmful components such as alkali compounds and sulfur which, upon their condensation from the rotary kiln exhaust gas, lead to caking in the lines conducting the gas. Moreover, these harmful components enter the raw meal pre-heating system together with the rotary kiln exhaust gas where they precipitate on the raw meal and are reintroduced into the rotary kiln with the pre-heated raw meal. A highly accumulating cycle of harmful substances can thus be formed in the burning process. In order to avoid this disadvantage, it is conventional to draw off a portion of the hot rotary kiln exhaust gases from the burning process via a bypass and to discard it. The significant heat content of the thermally highly valuable exhaust gas of the rotary kiln is, however, lost from the burning process by this technique. As a result, the entire burning process can become uneconomical. Particularly in very large cement manufacturing systems, it can no longer be justified in terms of heat efficiency to discard too much rotary kiln exhaust gas containing harmful substances without exploiting its heat content. By so doing, the manufacturing costs of cement, given today's energy costs and those to be expected in future, become too high.
SUMMARY OF THE INVENTION
In the inventive method only the smallest possible part of fuel is burned in the rotary kiln. The exhaust gas resulting therefrom is as small as possible and is drawn off by a bypass in an amount ranging from 0 through 100% before its use for raw meal pre-heating and/or raw meal calcination.
In the inventive method, a high degree of calcination of the raw meal is carried out outside of the rotary kiln in the calcinating stage so that the heat energy to be supplied to the rotary kiln is as small as possible. This smallest possible amount of heat energy to be supplied to the rotary kiln is produced by burning the smallest possible amount of fossil fuel in the rotary kiln. As a result, the smallest possible amount of combustion gases arise in the rotary kiln. By so doing, the rotary kiln can be built relatively short without a negative influence on the heat transfer between gas and material. Investment costs are thus saved; on the other hand, due to the reduction of the amount of rotary kiln exhaust gas, the concentration of the volatilized harmful substances such as alkali compounds and sulfur in the exhaust gas increases. For this reason alone, as well as because of the reduced amount of exhaust gas, whose heat content is likewise reduced, the partial or complete removal and rejection of this rotary kiln exhaust gas via a bypass can be economically justified.
The heat efficiency of the inventive method results from, and the removal of the rotary kiln exhaust gas from the burning process is above all profitable when, a greater percentage of the entire amount of rotary kiln exhaust gas is drawn off via a bypass as this amount of rotary kiln exhaust gas is made smaller. At the same time, the dimensions of the rotary kiln can be reduced all the more since less fossil fuel is burned in the rotary kiln.
To further increase the heat efficiency of the inventive method, and further reduce the amount of rotary kiln exhaust gas, at least one part of the fossil fuel burned in the rotary kiln can be replaced by means of heat generators which cause no exhaust gas in the rotary kiln. By so doing, the concentration of harmful substances in the rotary kiln exhaust gas increases even further and the heat losses due to the rejection of this exhaust gas become even smaller. This method will be particularly profitable if a significant part of the total amount of rotary kiln exhaust gas, approximately between 50 through 100%, is drawn off via a bypass and is removed from the burning process. Since the amount of exhaust gas from the rotary kiln has been even further reduced, the dimensions of the rotary kiln can be made even smaller.
The heat generators causing no exhaust gas in the rotary kiln can consist, for example, of electrical heating elements such as resistance or induction heaters, transmitters of high-energy rich beams such as beams of accelerated electrons for irradiation of the material, solar energy heaters or the like.
An improved burning system for the manufacture of mineral burning products, such as cement clinker from raw material, has a raw meal pre-heater, a calcinator which produces a high-degree of calcination of the raw meal, a rotary kiln and a clinker cooler. The ratio of the length of the rotary kiln to its inside diameter is smaller than 14:1 and preferably lies in a range of 7:1 through 11:1. A bypass line for the removal of rotary kiln exhaust gas is connected at the material intake end of the kiln to the rotary kiln exhaust gas channel leading to the calcinator or, respectively, raw meal pre-heater. This inventive burning system, thus, has a bypass line for the removal of rotary kiln exhaust gas. A rotary kiln with a relatively very small specific kiln length may thus be used. The use of the bypass line is all the more economically justifiable the shorter the rotary kiln is and the less fossil fuel is burned in the rotary kiln. It is precisely the intensive thermal and chemical preparation of the material for sintering and clinkering in the rotary kiln which allows the ¢working length" of the rotary kiln to be significantly shortened, insofar as this length is required for the preparation for the sintering and, thus, to significantly shorten the over-all rotary kiln. Said preparation is attainable with the assistance of a high-degree of precalcination.
Thus, surprisingly, it is possible to reduce the specific kiln length by approximately one-half with respect to the value standard up to now in a rotary kiln which is designed for modern dry processes for burning intensely pre-calcinated material into products of the burning process such as cement clinker. Expressed in numbers, the ratio of kiln length to the inside kiln diameter in such a rotary kiln is reduced from the previous approximately 16:1 to 8:1. A few advantages of the inventive burning system with short rotary kiln with respect to a system with traditional rotary kiln are the following:
Less kiln raw material, less kiln brick lining subject to wear, less surface radiating heat, therefore lower heat losses, lower weight, therefore also the need of lower driving power, and heat expansion is no longer such a problem. With less heat expansion, more favorable conditions exist for kiln seatings and seals.
In all, lower investment and operating costs of the burning system thereby ensue along with the advantage that, as a result of keeping the amount of exhaust gas as small as possible, a partial or complete removal of this exhaust gas from the burning process can now be economically justified.
Alternately, it has been found advantageous to incorporate non-fossil fuel heat generators in the calcining unit. These additional heat generators can supply about 20% of the total heat requirement of the calcining unit. The remaining 80% can be supplied by the fossil fuel burning elements in the calcining unit.
The use of non-fossil fuel heating elements in the calcining unit contributes to a saving of valuable fossil fuel as well as a minimization of the overall dimensions of the rotary kiln. Infrared radiators or electric heating units can be used in the calcining section.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a burning system for cement clinker manufacture with a short rotary kiln and bypass for rotary kiln exhaust gas;
FIG. 2 illustrates an embodiment of the burning system that is different from that of FIG. 1;
FIG. 3 illustrates the short rotary kiln of the burning system of FIG. 1 in a longitudinal section and in enlarged representation;
FIG. 4 illustrates a short rotary kiln designed differently from that of FIG. 3; and
FIG. 5 is a schematic diagram of a burning or sintering installation incorporating non-fossil fuel heat generators in the calcining unit as well as in the rotary kiln.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Not by way of limitation, but by way of disclosing the best mode of practicing our invention and by way of enabling one of ordinary skill in the art to practice my invention, there are disclosed in FIGS. 1-5 alternate embodiments of our invention.
The burning system of FIG. 1 exhibits a rotary kiln 10 to which a raw meal pre-heater 11 and a calcinator 12 are pre-connected and to which a clinker cooler 13 is post-connected. Cement raw meal 14 flows from the top toward the bottom through the pre-heater 11 and calcinator 12 in a combined counterflow/direct flow to the hot exhaust gases leaving the rotary kiln 10 and/or to the hot exhaust air of the cooler 13. These exhaust gases are drawn off by means of the induced-draught blower 15. The raw meal pre-heater 11 consists of cyclone heat exchangers 16, 17, 18. To induce the intense or high-degree of calcination of the cement raw meal before the meal enters into the rotary kiln 10, fuel B 1 is supplied between the cyclone heat exchangers 18 and 19 and fuel B 2 is supplied between the heat exchangers 19 and 20 as seen in the direction of flow of the cement raw meal. In the first burning stage or fuel burning point B 1 , approximately 30% of the calcining work is carried out, approximately 70% in the second burning stage B 2 . Preferably, the two burning stages utilize various types of inferior fuels. In the lower burning stage, fuel B 2 of every type is burned in a gas atmosphere that is formed from the cooler exhaust air supplied via the tertiary air line 21 and, under certain conditions, of rotary kiln exhaust gas. The fuel B 2 and gas from line 21, upon intimate mixing with the raw meal pre-heated in the raw meal pre-heater burns in such a manner that the heat or combustion is directly communicated to the raw meal and is employed to produce the desired intense or high-degree of calcining. A bypass line 22 for the removal of rotary kiln exhaust gas containing harmful substances is arranged in the rotary kiln exhaust gas channel to the calcinator 12 or, respectively, raw meal preheater 11. The highly calcined cement raw meal enters into the rotary kiln 10 through line 23.
As shown in FIG. 3, the rotary kiln 10 has a ratio of the length L to the inside diameter D of approximately 8:1 and therefore has an unusually small specific kiln length.
A burning location or point 24a in which fossil fuel B 3 is burned is located at the discharge end of the rotary kiln 10 and is supplied via a primary air line 24. An additional supply of fuel B 4 particularly in lumpy form can be provided at a fuel burning point near the material intake end of the rotary kiln 10 via line 25. The solid fuel is preferably composed of unground coal pieces which quasi-swim on the raw meal and burn in the raw meal almost without flame, whereby the efficiency of the heat transfer is very high. The finished, burned cement clinker is cooled in the clinker cooler 13. The cooled material leaves cooler 13 via line 26. Fresh air streams into the cooler through line 27; a part of the cooler exhaust air is drawn off via line 28.
Since the inventive short rotary kiln 10 has a comparatively small specific kiln length, it can be seated on only two seating locations 29 and 30. The drive of the rotary kiln is indicated with 31.
The rotary kiln 10a of FIG. 4 has a greater interior diameter in the area of its material introduction or, respectively, in its sintering preparation zone than in the remaining rotary kiln longitudinal area. In the area with expanded diameter, the interior walls of the rotary kiln exhibit ceramic lifting installations 31a for lifting and scattering the material to be sintered, whereby the heat transfer between rotary kiln exhaust gas and material is intensified. Moreover, the dwell time of the material in the rotary kiln is increased with a simultaneous reduction of the gas velocity due to the fact that the sintering preparation zone is expanded in cross section. As a result, the heat transfer between gas and material is likewise improved.
In the burning system of FIG. 2, parts coinciding with FIG. 1 are provided with the same reference numerals. A mixing chamber 33 in which hot rotary kiln exhaust gas of approximately 1300° C. is very quickly cooled to approximately 400° through 600° C. by admixture of cold air supplied via blower 34 and/or addition of water and/or raw meal is arranged above the kiln intake head 32 of the rotary kiln 10.
The cooled rotary kiln exhaust gas is drawn off via the bypass line 22. Preferably, approximately 20 through 100% of the total amount of rotary kiln exhaust gas is drawn off via the bypass. This percentage of the amount of exhaust gas is all the greater the smaller the total amount of rotary kiln exhaust gas is. The 20% through 100% of the exhaust gases drawn off via the bypass line 22 is cooled from about 1300° C. to 400° C. through 600° C. by the addition of cold air.
The remaining amount of rotary kiln exhaust gas is conducted into the lowest cyclone 20 of the cyclone heat exchanger system via the ascending line 35 of the calcinator 12 and/or via a line 36. The stream of material 37 leaving the cyclone 19 is divided into two streams by a distribution element which is not illustrated. One partial stream of the material is conducted into the ascending line 35 of the calcinator 12 designed as a burning segment. The other partial stream of the material is introduced into the exhaust gas line 36. The rotary kiln exhaust gas in line 36 is cooled by the partial stream of the material to such a degree that this rotary kiln exhaust gas as well as the exhaust gas in the calcining device 12 exhibit an approximately identical temperature of approximately 800° through 900° C. upon their mixing in cyclone 20. In this manner, no kiln exhaust gas containing harmful matter arrives in the descending line 35 of the calcinator 12 designed as a burning segment.
The distribution of the amount of rotary kiln exhaust gas not drawn off by the bypass line 22 to the exhaust gas line 36 and/or to the ascending line 35 of the calcinator 12 can be accomplished by means of regulating elements 38, 39 or, respectively, 41 in lines 36, 21 or, respectively, 22.
The burning location 24a or, respectively, the burning locations 24a and 25a of the rotary kiln 10 which produce exhaust gases in the rotary kiln 10 are at least partially replaced in the sample embodiment of FIG. 2 by means of heat generators arranged on or, respectively, in the rotary kiln. These heat generators cause no exhaust gases in the rotary kiln and are symbolically illustrated by means of many small arrows with the designation B 5 . A numerical example follows.
Of the heat energy to be supplied to the total burning process, 65% must be supplied to the pre-heater 11 and the calcinator 12 and the remaining 35% must be supplied to the rotary kiln 10. Up to now, this 35% heat requirement in the rotary kiln 10 was provided by means of the single burning location 24a. In order to reduce the amount of rotary kiln exhaust gas and, thus, also the heat loss that arises due to the removal of rotary kiln exhaust gases containing harmful substances via the bypass 22, the amount of the fossil fuel B 3 can be inventively reduced to such a degree that it provides only 15% of the heat requirement in the rotary kiln instead of 35%; the heat generators B 4 and B 5 produce no exhaust gases in the rotary kiln 10, and each provides the remaining heat requirement of, for example, respectively 10%, so that the total 35% heat energy is then generated in the rotary kiln.
The heat generators B 5 are, for example, electric heating elements such as resistance or induction heaters which are built into the fireproof lining of the rotary kiln and keep the interior wall temperature at, for example, 1200° C. The rotary kiln 10 is advantageously equipped with a heat insulation 40. Upon the reduction of the fuel B 3 for the burning location 24a, a transmitter B 6 of high-energy rich beams can be arranged in its area, which beams then replace the missing heat requirement of the rotary kiln by means of radiation chemical treatment of the material. Such a transmitter 25a can also be arranged at the material intake side of the rotary kiln.
The amount of fossil fuel B 3 supplied to the rotary kiln 10 should not be completely reduced to zero. A certain amount of exhaust gas in the kiln 10 is necessary. The volatilizing harmful components such as alkali compounds and sulfur condense on the dust particles suspended in the exhaust gas in the rotary kiln 10.
It will be understood that the invention is also employable in burning systems in which the gas and material are conducted in the pre-heater and calcinator in two or more series parallel to one another.
Additionally, it has been found that the heat energy supplied by the burners or burning locations B 1 , B 2 in the calciner 12 of FIG. 1 or the burning locations or burners B 2 in the calciner 12 of FIG. 2 can be partly replaced by heating elements that do not produce exhaust gases. FIG. 5 which is an installation corresponding to FIG. 2 shows an additional set of heat generators B 7 arranged on or in calciner 12. The heat generators B 7 produce no exhaust gases in calciner 12. Heat generators B 7 can be used in combination with heat generators B 5 or B 6 . Alternatively, heat generator B 7 can be used without heat generators B 5 , B 6 .
Of the total heat energy required by the calciner 12 approximately 20% can be supplied by heat generators B 7 . The remaining 80% of the necessary heat energy to be supplied to the calciner 12 can be produced by the combustion of fossil fuels in burners or burning elements B 1 , B 2 , or B 2 alone. The exhaust gases from the fossil fuels contribute to keeping the raw meal passing through the calciner 12 in suspension.
The additional heat generators B 7 can be used with kilns shown in FIGS. 3, 4, as well as in the installation of FIG. 1. Infrared radiators can be used as the heat generators B 4 -B 7 . Available infrared heaters can heat the irridiated material to approximately 1000° C. and higher. Electric heating units such as resistance or induction heaters can also be used. High energy particle beams, produced by an appropriate source, such as accelerated electrons, can be used as heat generators B 4 -B 7 , to irridiate and heat the raw meal being calcined. Solar heaters can also be used for heating elements B 4 -B 7 .
Although various modifications might be suggested by those skilled in the art, it should be understood that we wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art. | The invention relates to a method for burning fine-grain material, particularly for the manufacture of cement clinker from cement raw meal. The material is thermally treated in a multi-stage burning process with a pre-heating stage, a calcining stage with a high-degree of calcination, a sintering stage in a very short rotary kiln and a cooling stage. Fuel is introduced both into the sintering stage in the short rotary kiln as well as into the calcinating stage. Hot exhaust air from the cooling stage is supplied both to the sintering stage as well as to the calcining stage as furnace air. The invention also relates to an apparatus for the manufacture of mineral products of the burning process such as cement clinker. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates generally to overload protection arrangements for electric motors and more particularly to line break protection systems for multispeed hermetic motor arrangements.
Thermal overload protection for motors is a highly developed art with a particularly inexpensive and readily available protective device being the line break motor protector. Such devices may take the form of a bimetallic disc or other element which normally connects two terminals together but which when overheated snaps to another position opening the circuit between those terminals. This bimetallic disc or other member may be self-resetting when it cools or may require a manual reset. The thermal protector may include a heating element in series between the two terminals so that the temperature responsive bimetallic member may actuate to open the circuit between the terminals in response to excessive current flow between those terminals so that the thermal protector is responsive to excessive current, excessive temperature of its environment or some combination of the two, any of which may be indicative of an overload condition. Such thermal protectors may include additional terminals and additional heating elements for certain installations.
Another highly developed technology is that of multiple speed motors. Multiple speed single-phase alternating current operation of an electric motor is frequently achieved by operating that motor in a selected one of several possible pole number configurations. This may be achieved by providing independent windings for the several different pole configurations or by providing windings which are differently interconnected to achieve the different pole configurations, with either option being available for either the auxiliary or starting winding, or the main or running winding.
When a given motor winding is active in more than one pole configuration, overload protection has heretofore taken the form of one or more temperature sensors in thermal contact with the motor windings and connected to an external solid state logic module, as illustrated, for example, in U.S. Pat. No. 3,978,382. Such systems are subject to a number of drawbacks. The cost of the sensors and logic module is significant. Separate and essentially independent arrangements are required for detecting excessive current and detecting winding temperature increase. System complexity increases the likelihood of system malfunction. Such systems fail to effectively utilize available high production and therefore low cost parts.
SUMMARY OF THE INVENTION
Among the several objects of the present invention may be noted the provision of an economical and reliable overload protection scheme for a multispeed motor; the replacement of expensive solid state protection arrangements for multispeed motors with relatively inexpensive and readily available line break protectors; the provision of a multispeed motor employing line break motor protectors wherein certain of the protectors are operational in more than one speed determining pole configuration; and the provision of a line break motor protector arrangement wherein restart of the motor is prevented until all overload actuated protectors are reset.
These as well as other objects and advantageous features of the present invention will be in part apparent and in part pointed out hereinafter.
In general, overload protection for a pole changing motor is provided by a line break motor protector in circuit with at least one auxiliary winding and with one main winding section of the motor for interrupting current flow through the auxiliary and one main winding section in the event of an overload condition, along with a second line break motor protector in circuit with another main winding section for interrupting current flow through that other section in the event of an overload condition with both protectors being opertional in more than one pole configuration of the motor.
BRIEF DESCRIPTION OF THE DRAWING
The drawing schematically illustrates a single phase two speed pole changing motor with main windings operable in each of the two speed determining pole configurations and a pair of auxiliary windings having different pole numbers along with the overload line break motor protectors which are operational in both pole configurations.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing in greater detail, a single phase two speed pole changing motor has main winding sections 11 and 13 each of which is operable in both of the speed determining pole configurations with the windings 11 and 13 connected in parallel for operation at a high speed corresponding to a two pole configuration and with windings 11 and 13 connected in series for operation at a lower speed corresponding to a four pole configuration in which two poles are consequent poles. Independent auxiliary or start windings 15 and 17, with winding 15 illustrated as a four pole start winding and winding 17 illustrated as a two pole or high speed start winding, are also located in the motor stator. An additional or extended main winding 19 may be provided and as illustrated is employed only in the two pole or higher speed motor configuration, with current flowing through that extended main winding and then branching through the two parallel paths of main winding sections 11 and 13. Pole changing motors of the variety thus far described are well known in the single phase induction motor art and are sometimes employed in hermetic environments such as, for example, for driving air conditioner compressors.
Pole configuration selection is accomplished by a pair of relays or contactors having relay actuating coils 21 and 23 and corresponding sets of contacts 25 and 27, with contact set 25 corresponding to the low speed actuating relay coil 21, while contact set 27 corresponds to the high speed relay actuating coil 23 being closed thereby.
Start up of the motor in the low speed configuration is facilitated by the potential relay 29 while start up in the high speed pole configuration is facilitated by potential relay 31. Each of these potential relays is of known design and includes a sensing coil 33 or 35 which when the voltage across the corresponding start winding becomes sufficiently high functions to open the contact set 37 or 39, disabling the corresponding start windings.
In normal operation the speed at which the motor is to operate is selected by positioning the double pole single throw switch 41 in the position illustrated for low speed operation or moving that switch so as to close on contact 43 and select high speed operation. Thus, when a pilot voltage such as might be induced by the closing of a thermostat is applied between lines 45 and 47, relay coil 21, as illustrated, will be actuated, closing each of the three contacts associated with the contact set 25. With line voltage applied to the lines 49 and 51, the start winding current may be traced beginning with line 49 passing through the start capacitor 53 by way of closed contacts 55, 37 and 57 through the four pole start winding 15, through the line break motor protector 59 to line 51. Still in the low speed or four pole configuration, the main winding current may similarly be traced beginning with line 49 through closed contacts 61 by way of line 63 and a second line break motor protector 65 through the series combination of main winding sections 11 and 13 and then through the first line break motor protector 59 to line 51.
The line break motor protectors 59 and 65 are of a known and readily commercially available design employing heating elements 67, 69 and 71 and self-resetting snap-acting bimetallic elements 73 and 75. Such temperature responsive protectors are placed in good heat transfer relation with motor windings and are available for example from Texas Instrument Company with protector 59 bearing their designation 15HM and protector 65 designated 4HM for one embodiment of the invention. A conventional run winding capacitor 77 and 78 may be provided, if desired.
In the four pole or low speed configuration, a temperature increase of the windings in the region of either of the protectors 59 and 65, or excessive main winding current so as to heat the heaters 67 or 71 may cause one of the two bimetallic strips 73 or 75 to open and the opening of either of these contacts completely disables the motor until that bimetallic element cools and closes again. Also an overload condition where excessive start winding current flows through the heater 69 may cause protector 59 to disable the system. Since the protectors 59 and 65 are in series in the low speed configuration, both must be closed or reset for motor operation, however, in the two pole configuration, some additional problems are present.
If switch 41 is moved from the position illustrated so as to close an contact 43, the high speed relay coil 23 is energized, closing the contact set 27. Note that the switch 41 functions as a mechanical lock out arrangement so that it is not possible to energize both coils 21 and 23 at the same time. Thus, in the two pole configuration, contact set 25 remains open. A further lock out arrangement is provided by having a set of normally closed contacts 79 which are opened when the relay coil 23 is energized and similarly having a set of normally closed contacts 81 which are opened when relay coil 21 is energized.
In the two pole or high speed configuration, start winding current flows by way of line 49 and the start winding capacitor 53 which is common to the two configurations by way of the closed contacts 83, 39 and 87 through the two pole start winding 17, protector heater 69 and contacts 75 to line 51. When the voltage across start winding 17 increases, indicating adequate speed, this voltage is sensed by coil 35 and contacts 39 open to disengage the start winding. The main winding current flow is from line 49, closed contacts 89 and the extended main winding section 19 whereupon the current flow branches through the two parallel connected main winding sections 11 and 13 with the current through main winding section 13 passing by way of the line break motor protector 59 to line 51 while that through main winding section 11 passes through the protector 65 and by way of line 63 and closed contacts 85 to line 51. Thus, each of the protector heaters is subjected to a different portion of the main winding current and additionally the three terminal protector 59 is responsive to the start winding current. Potential relay 31 functions as described previously to disconnect the four pole start winding when the motor reaches sufficient speed.
Suppose now that the motor is running in its four pole configuration and for some reason main winding 11 draws excessive current. This excessive current will heat the heating element 71, causing the bimetallic member 73 to open, interrupting the current flow in main winding section 11. Once protector 65 opens, the current flow in start winding section 15 increases substantially, heating element 69, and causing the bimetallic member 75 to open the second branch, thus disabling the motor.
The protectors 59 and 65 are of the self-resetting variety and in the two pole configuration the resetting of either one will reenergize the motor with only one of the two main winding sections 11 or 13 in the circuit causing repetition of the overload and cut out of the protector. Thus, when one of the protectors resets, there will be a cycling of reset, disengage, reset, etc. To avoid this cycling of the protectors, relay actuating coil 91 is connected across protector 59, specifically in parallel with the series combination of the heating element 67 and contacts 75. So long as contacts 75 remain closed, the resistance of heating element 67 is quite low and there is insufficient voltage to actuate the relay coil 91, however, when the bimetallic contact 75 opens, essentially line voltage is applied to relay coil 91, actuating that coil and closing relay contact 93 while opening the normally closed set of contacts 95, thus placing the motor in its low speed configuration where the two protectors are in series and both must reset before the motor restarts. If protector 59 resets before protector 65, the relay coil 91 will be deenergized and if switch 41 is in the high speed position, the motor is returned to its high speed pole configuration and again begins the undesirable reset cycling, however, the reset time of the protectors is a design parameter which is readily varied and by providing the protector 65 with a reset time which is less than that of protector 59, allows protector 65 to close first, thereafter protector 59 closes. The motor then starts with relay 91 being deenergized, returning the motor to whichever pole configuration has been selected by switch 41. Without relay 91 and its associated contacts, if protector 65 resets when the switch 41 was in the high speed or two pole configuration, current flow through main winding section 11 would be reestablished and protector 65 again would over heat and disconnect, again resulting in the undesirable cycling of that protector.
From the foregoing it is now apparent that a novel overload protection arrangement for a multiple speed single phase motor has been described meeting the objects and advantageous features set out hereinbefore as well as others and that modifications as to the precise configurations, shapes and details may be made by those having ordinary skill in the art without departing from the spirit of the invention or the scope thereof as set out by the claims which follow. | Overload protection for a multispeed motor is provided in the form of a plurality of line break motor protectors positioned in good heat transfer relation with the motor windings and having heating elements in circuit with the motor windings to be responsive to excessive winding current and/or excessive winding temperature to disable the windings. Certain of the line break motor protectors are operational in more than one motor speed configuration. The line break motor protectors may be of the self-resetting temperature sensing variety and circuitry is included to insure that the motor does not restart until all protectors are reset subsequent to an overload condition. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to gas turbine power plants and, more particularly, to a gas turbine power plant using the deoxidized reaction principle.
2. Description of the Prior Art
Various methods of producing electricity are well known in the art. Hydro-electric plants, fossil fuel plants and nuclear power plants have all been used to produce electricity by the use of gas turbines. Similarly, gas turbine power plants are numerous. Representative patents in the general area of this invention are U.S. Pat. Nos. 3,477,228 (Gas Turbine Power Plant); 3,975,913 (Gas Generator and Enhanced Energy Conversion System); 4,388,892 (Process and Apparatus for Generation of Steam via Catalytic Combustion); 3,990,245 (Energy Converter Device); 4,209,992 (Power Generating Method and Apparatus); 4,503,682 (Low Temperature Engine System). Although these systems have been and are being used extensively for the production of electricity, they all have serious drawbacks. Hydro-electric plants are dependent upon a river and a dam for operation. Approval delays from environmental groups and governmental agencies coupled with high construction costs make hydro-electric plants a costly venture. Fossil fuel plants have associated with them the inherent problems of non-renewability of fossil fuel resources and inherent pollution problems. Nuclear power plants are not only expensive and time-consuming, having associated with them also the approval delays from environmental groups and governmental agencies coupled with high construction costs, but also have the obvious danger factors associated with any nuclear reaction. The fuels associated with these power plants are costly to locate and manufacture and produce in sufficient quantities.
Consequently, a need exists for improvements in electrical power plants for the production of electricity which will result in a power plant which is not dependent upon any particular location, would not be subject to environmental and governmental agency approvals, and which can be constructed at reduced levels of capital investments.
SUMMARY OF THE INVENTION
It is, therefore, one of the principal objectives of this invention to provide a method and apparatus for producing electrical power designed to satisfy the aforementioned needs not heretofore produced by the prior art.
In accordance with the invention, described herein, atmospheric air is caused to flow through analyzing and controlling means which produce a low hydrogen to air ratio mixture. A controlled amount of nitrogen gas could also be introduced into the air stream for the purpose of reducing the oxygen content of the air stream. This produces a low H 2 /air ratio. This low hydrogen to air ratio mixture is then passed into a reaction chamber filled with reactants which cause an exothermic chemical reaction to take place within the reaction chamber producing a discharge air stream at an elevated temperature. This discharge air stream then passes in heat exchange relationship with a working fluid such as a liquid hydrocarbon which evaporates and passes through a turbine which is connected by means of a reduction gear to a generator which then produces the electricity. The method comprises the steps of: drawing into the system a large mass of atmospheric air by means of a compressor, filtering out any dust particles and gases, regulating the amount of air flow based upon system demand, regulating and controlling the hydrogen to air ratio mixture by the use of analyzers and hydrogen and nitrogen flow meters, analyzing the air stream to determine the correct hydrogen and oxygen content, venting the air stream to atmosphere until the proper hydrogen to air ratio is achieved, passing the air stream through a series of check valves and flame arrestors into a reaction chamber filled with a hydrogenating catalysis material, passing the hot gas discharge stream from the reaction chamber through an electro ferrous accumulator removing any ferrous particles in the air stream, passing the hot gas discharge stream through another flame arrestor, preventing heat loss from the hot gas discharge stream, passing the hot gas discharge stream in heat exchange relationship with a liquid hydrocarbon such as freon through an evaporator causing the freon to vaporize, passing the vaporized freon through a turbine which is coupled by means of a reduction gear to a electrical generator, allowing the hot expanding discharge gases from the turbine to pass into a water-cooled heat exchanger which condenses the freon, passing the liquid freon back to the freon evaporator to complete the circuit, and supplying some of the electrical power generated to run a hydrogen generator producing some of the hydrogen needed for the controlling and monitoring steps.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be hereinafter more fully described with reference to the accompanying drawing in which:
FIG. 1 is a schematic representation partly in section of an embodiment of a power plant according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The method of producing electricity according to the present invention begins with compressor 10 drawing in a mass of air 12 into the system. The air 12 is pulled into a filter 14 to remove any dust that may be present in the air. The air is next pulled through a molecular sieve 16 to further filter out any undesirable gases such as carbon monoxide and carbon dioxide which may be present in the air mass 12. The air mass 12 is then passed through a controllable guide vane nozzle assembly 18, which controls the quantity of air entering the system determined by the power demand on the system. When the vane positions are increased, more air is allowed into the process which results in an increase in the total process flows and a corresponding increase in temperature exchange. The air mass 12 then flows past a manifold consisting of an inlet process hydrogen gas valve 20 and inlet process nitrogen gas valve 22. These valves are initially closed during start-up and are later opened when needed to control the hydrogen and oxygen content of the air mass. As the air stream leaves the compressor 10, its chemical make-up is analyzed by two separate analyzer sample lines. Oxygen sample line 24 determines the oxygen content of the air stream. Hydrogen sample line 26 is used to determine the percentage of hydrogen gas present in the air stream. The air stream then flows through an orfice plate 28, which is connected to sample line 30, which is attached to an air stream flow calculating ratio computer program controller 32. This air stream flow calculating ratio computer program controller 32 is connected to the inlet process hydrogen valve 20, the inlet process nitrogen valve 22, controllable guide vane nozzle assembly 18, control valve 53b, and the oxygen sample line 24 and the hydrogen sample line 26 by control line 37. Controller 32 functions to monitor and maintain the hydrogen to air ratio in the air stream keeping the hydrogen content less than four percent and ideally around two percent. As the air flows past the orifice plate 28, it is discharged to the atmosphere through vent valve 34. Immediately downstream from vent valve 34 is a control valve 36 which is normally closed during start-up, which allows the air stream to flow through the vent valve 34 to atmosphere establishing the systems air flow rate and pressure. When the desired constant air flow is maintained and determined by the controller 32, the controller sends a signal to the inlet process hydrogen valve 20 to open for a pre-programmed flow of hydrogen gas to enter the air stream that corresponds with the particular air flow. As the hydrogen content of the air increases, analyzer lines 24 and 26 monitor the content in connection with the controller 32. With the correct percent of hydrogen gas in the air stream established, a signal can be sent along control lines 38 and 39 to open the control valve 36 and close the vent valve 34. The air stream now flows through control valve 36, past a check valve 40 through a flame arrestor 42 and into the reaction chamber 44. The reaction chamber 44 is filled with a reactant 46 which is a hydrogenating catalyst. The catalyst could be selected from the group of platinum, palladium, silver, zirconium, rhodium, vanadium, iron, nickel, lanthanides, actinides, oxides of the preceding materials, and carbon black. When the low hydrogen content air stream comes into contact with the reactant catalyst 46, a chemical reaction takes place which bonds the metered amount of hydrogen gas to a certain percentage of the oxygen gas present in the air stream. This bonding results in a temperature rise of approximately 400 degrees Fahrenheit for each one percent oxygen bonded together from the catalytic reaction. The hot deoxidized gas stream flows from the reaction chamber 44 through an electromagnetic ferrous accumulator 48 which removes any ferrous particles from the air stream which could cause a system shut-down and then further flows through flame arrestor 50 to a heat exchanger evaporator 52. Inside the heat exchanger evaporator 52 is a working fluid 54 such as freon which exchanges heat with the hot gas stream. This heat exchange relationship causes the hot gas stream to condense, causing water to flow out drain 53. The gas stream then leaves the heat exchanger evaporator 52 and is directed back to the compressor 10 through line 53a through control valve 53b. If the system is running on atmosphere air, then control valve 53b will be closed and then the air stream would escape to atmosphere through drain 53. This heat exchange causes the working fluid 54 to vaporize, creating a high pressure gas stream which flows into a turbine 56 which is coupled through coupler 56a to a generator 58 which produces the electrical power. The hot expanding gas stream then discharges from the turbine 56 into a water-cooled heat exchanger 59 and is pumped back to the evaporator 52 by means of pump 60. Water is circulated from a cooling tower 62 by means of pump 64 through the water-cooled heat exchanger 59 to cool the expanding gas stream as it leaves the turbine. Part of the electricity that is produced can be used to run an electrolysis unit 68 which can be used to produce some or all of the hydrogen that is needed for the process which can be introduced into the system through the hydrogen control valve 20. Further, heat loss can be prevented from the process line from the reaction chamber 44 to the heat exchanger evaporator 52 by use of a vacuum jacketed line, which is well known in the art. Safety features could be readily incorporated into the process, including the use of temperature sensoring of the reaction chamber wired to a shut-down relay system for over-temperature protection of the catalyst. Other safety features well known in the art could be incorporated into the system for the hydrogen content control of the air stream to further cause an automatic shut-down of the system if the hydrogen content exceeds a predetermined amount. If the hydrogen content of the air stream is out of balance, then the controller 32 can close the control valve 36 and open the vent valve 34 to vent the air stream to the atmosphere.
This invention has been described with respect to a specific embodiment thereof. However, the invention should not be construed as limited thereto. Various modifications would be apparent to those skilled in the art and can be made without departing from the scope of this invention, which is limited only by the following claims. | An apparatus and method of producing electricity comprising passing a low hydrogen content (zero to four percent) air stream over a hydrogenating catalyst in a reaction chamber thereby producing a hot discharge gas which is used to vaporize a liquid hydrocarbon which turns a turbine coupled to a generator. | 5 |
[0001] This application is a continuation of U.S. application Ser. No. 13/165,741 filed on Jun. 21, 2011, which is a continuation of U.S. application Ser. No. 12/470,787 filed on May 22, 2009, now U.S. Pat. No. 7,982,237 and which claims the benefit under 35 U.S.C. §119 of Korean Patent Application No. 10-2008-0048241, filed May 23, 2008, which are hereby incorporated by reference for all purpose as if fully set forth herein.
BACKGROUND
[0002] The embodiment relates to a light emitting device package.
[0003] A light emitting device (LED) is a semiconductor device to convert a current into a light. Since a red LED has been commercialized, the red LED, together with a green LED, is used as a light source of electronic devices including information communication equipment.
[0004] The light emitting device package includes a light emitting part and a phosphor. In this case, the light emitting part emits light having a first wavelength and the phosphor emits light having a second wavelength, so that the light emitting device package emitting white light can be realized. However, since the light emitted from the phosphor is absorbed into the light emitting part, light efficiency may be reduced. In addition, color deviation may occur due to the difference of optical paths of the light emitted from the light emitting part and transmitted to the phosphor.
BRIEF SUMMARY
[0005] The embodiment provides a light emitting device package capable of improving light efficiency and reducing color deviation.
[0006] According to the embodiments, a light emitting device package includes a semiconductor substrate comprising a first surface at a first depth from an upper surface of the semiconductor substrate and a second surface at a second depth from the first surface; and a light emitting part on the second surface of the semiconductor substrate.
[0007] According to the embodiments, a light emitting device package includes a semiconductor substrate comprising a groove having a multi-layer structure; a light emitting part in the groove of the semiconductor substrate; a first conductive layer electrically connected to a first electrode of the light emitting part; and a second conductive layer electrically connected to a second electrode of the light emitting part.
[0008] According to the embodiments, a light emitting device package includes a substrate comprising a recess; a light emitting chip on the substrate; and a first conductive layer electrically connected to the light emitting chip, wherein the first conductive layer comprises at least one metal layer electrically connected to the light emitting chip on an outer circumference of the substrate.
[0009] The light emitting device package according to the embodiment can improve light efficiency and can reduce color deviation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIGS. 1 to 11 are sectional views showing the manufacturing process of a light emitting device package according to a first embodiment;
[0011] FIG. 12 is a sectional view showing a light emitting device package according to a second embodiment;
[0012] FIG. 13 is a sectional view showing a light emitting device package according to a third embodiment;
[0013] FIG. 14 is a sectional view showing a light emitting device package according to a fourth embodiment;
[0014] FIG. 15 is a sectional view showing a light emitting device package according to a fifth embodiment;
[0015] FIG. 16 is a sectional view showing a light emitting device package according to a sixth embodiment;
[0016] FIG. 17 is a sectional view showing a light emitting device package according to a seventh embodiment; and
[0017] FIG. 18 is a sectional view showing a light emitting device package according to an eighth embodiment.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0018] Hereinafter, the embodiments will be described in detail with reference to accompanying drawings.
[0019] In the description of the embodiments, it will be understood that, when a layer (or film), a region, a pattern, or a structure is referred to as being “on/over” or “below/under” another substrate, another layer (or film), another region, another pad, or another pattern, it can be “directly” or “indirectly” “on/over” or “below/under” the other substrate, layer (or film), region, pad, or pattern, or one or more intervening layers may also be present. Such a position of the layer has been described with reference to the drawings.
[0020] The thickness and size of each layer shown in the drawings can be exaggerated, omitted or schematically drawn for the purpose of convenience or clarity. In addition, the size of elements does not utterly reflect an actual size.
First Embodiment
[0021] FIGS. 1 to 11 are sectional views showing the manufacturing process of a light emitting device package according to a first embodiment.
[0022] First, as shown in FIG. 1 , first and second masks 13 and 15 are formed on upper and lower surfaces of a semiconductor substrate 11 .
[0023] Next, as shown in FIG. 2 , in order to etch the semiconductor substrate 11 , a first pattern mask 13 a and a second pattern mask 15 a are formed. The first and second pattern masks 13 a and 15 a can be formed through a photolithography process.
[0024] The semiconductor substrate 11 can include single crystalline silicon, but the embodiment is not limited thereto. The semiconductor substrate 11 can be etched through a dry etching process or a wet etching process. When the semiconductor substrate 11 includes a silicon substrate, the first and second masks 13 and 15 can include a silicon nitride layer, but the embodiment is not limited. In addition, the semiconductor substrate 11 can be subject to a KOH wet etching process, but the embodiment is not limited thereto.
[0025] Thereafter, as shown in FIG. 3 , the etching process is performed to form a first semiconductor substrate 11 a having a first surface (or first groove) formed at a first depth from an upper surface thereof. In other words, the etch shape of the first semiconductor substrate 11 a can be adjusted according to the alignment of the first and second pattern masks 13 a and 15 a . Accordingly, the first semiconductor substrate 11 a can have the shape of a bathtub with the first surface formed at the first depth from the upper surface of the first semiconductor substrate 11 a , but the embodiment is not limited thereto.
[0026] Subsequently, as shown in FIG. 4 , the first and second pattern masks 13 a and 15 a can be removed from the first semiconductor substrate 11 a . For example, the first and second pattern masks 13 a and 15 a can be removed through the wet etching process, but the embodiment is not limited thereto.
[0027] Thereafter, as shown in FIG. 5 , a third mask 17 is formed on the first semiconductor substrate 11 a . The third mask 17 can include a silicon nitride layer or a silicon oxide layer, but the embodiment is not limited thereto.
[0028] Then, as shown in FIG. 6 , in order to etch the first semiconductor substrate 11 a , third and fourth pattern masks 17 a and 17 b are formed on upper and lower surfaces of the first semiconductor substrate 11 a . The third and fourth pattern masks 17 a and 17 b can be formed in a desired shape through a photolithography process, but the embodiment is not limited thereto.
[0029] Next, as shown in FIG. 7 , an etching process is performed to form a second semiconductor substrate 11 b having a second surface (or a second groove) formed in the first surface at a second depth. The etch shape of the second semiconductor substrate 11 b can be adjusted according to the alignment of the third and fourth pattern masks 17 a and 17 b . The etching process for the second semiconductor substrate 11 b can be performed along to a crystal plane (e.g., (100) or (111)) of a single crystalline substrate.
[0030] Thereafter, as shown in FIG. 8 , the third and fourth pattern masks 17 a and 17 b can be removed.
[0031] According to the first embodiment, as shown in FIG. 8 , the second semiconductor substrate 11 b can have a bathtub shape, in which a first surface A having a first depth h 1 on the basis of the upper surface of the semiconductor substrate 11 b is formed in a first region and a second surface B having a second depth h 2 is formed in a second region of the first surface A.
[0032] Thereafter, as shown in FIG. 9 , an insulating layer 19 can be formed on the second semiconductor substrate 11 b . The insulating layer 19 is formed for the electric insulation from a conductive layer formed in the subsequent process. The insulating layer 19 can include a silicon oxide layer, a silicon nitride layer, an aluminum nitride (AlN) layer, or a silicon carbide (SiC) layer, but the embodiment is not limited thereto.
[0033] Next, as shown in FIG. 10 , the conductive layer can be formed on the insulating layer 19 . The conductive layer can be electrically connected to a light emitting part that is formed in the subsequent process. First and second metal layers 21 a and 21 b can be formed on the insulating layer 19 , and third and fourth metal layers 23 a and 23 b can be formed below the insulating layer 19 .
[0034] Thereafter, as shown in FIG. 11 , a light emitting part 25 can be formed on the second semiconductor substrate 11 b . The light emitting part 25 can be realized in the form of a light emitting diode, but the embodiment is not limited thereto. The first metal layer 21 a and/or the third metal layer 23 a serving as a first conductive layer can be connected to a first electrode (not shown) of the light emitting part 25 , and the second metal layer 21 b and/or the fourth metal layer 23 b serving as a second conductive layer can be connected to a second electrode (not shown) of the light emitting part 25 .
[0035] The first metal layer 21 a and the second metal layer 21 b formed on the upper surface of the second semiconductor substrate 11 b can include a metal thin film having high reflectance, so that the light efficiency of the light emitting device package can be improved. In addition, the third metal layer 23 a and the fourth metal layer 23 b formed on the lower surface of the second semiconductor substrate 11 b can include metal having superior adhesive strength with an adhesive such as a cream solder or the like. This can improve electric/mechanical connection with metal interconnections formed on a printed circuit board in the subsequent surface-mount technology (SMT) process.
[0036] The first and second metal layers 21 a and 21 b can include a plurality of metal layers, and the upper most layer thereof can include aluminum (Al), silver (Ag), or APC (Ag, Pd, Cu) metal. In addition, the third and fourth metal layers 23 a and 23 b can include a plurality of metal layers, and the lower most layer thereof can include gold (Au), or copper (Cu).
[0037] A phosphor 27 can be formed on the light emitting part 25 , and a molding part 29 can be formed on the phosphor 27 . The phosphor 27 can receive light having a first wavelength band from the light emitting part 25 and can supply light having a second wavelength band. The second wavelength band can be longer than the first wavelength band. White light can be emitted based on the light having the second wavelength band from the phosphor 27 and the light having the first wavelength band from the light emitting part 25 . The molding part 29 can protect the phosphor 27 and the light emitting part 25 . The molding part 29 can include silicon, but the embodiment is not limited thereto.
[0038] According to the embodiment, as shown in FIG. 11 , the light emitting device package can include the second semiconductor substrate 11 b , the light emitting part 25 , the first metal layer 21 a , the second metal layer 21 b , the third metal layer 23 a , the fourth metal layer 23 b , the phosphor 27 , the insulating layer 19 , and the molding part 29 .
[0039] The second semiconductor substrate 11 b can be formed in the shape of a two-stage bathtub having the first surface formed at the first depth h 1 from the upper surface of the second semiconductor substrate 11 b and the second surface formed at the second depth h 2 from the first surface. The light emitting part 25 can be formed on the second surface of the second semiconductor substrate 11 b.
[0040] The first conductive layer including the first metal layer 21 a and the third metal layer 23 a can be connected to the first electrode of the light emitting part 25 , and the second conductive layer including the second metal layer 21 b and the fourth metal layer 23 b can be connected to the second electrode of the light emitting part 25 .
[0041] The first conductive layer can include the first metal layer 21 a provided on the second semiconductor substrate 11 b and the third metal layer 23 a provided below the semiconductor substrate 11 b . The first metal layer 21 a and the third metal layer 23 a can be electrically connected to each other at an outer peripheral surface of the second semiconductor substrate 11 b.
[0042] The second conductive layer can include the second metal layer 21 b provided on the second semiconductor substrate 11 b and the fourth metal layer 23 b provided below the semiconductor substrate 11 b . The second metal layer 21 b and the fourth metal layer 23 b can be electrically connected to each other at the outer peripheral surface of the second semiconductor substrate 11 b.
[0043] The phosphor 27 can be formed on the light emitting part 25 , and the molding part 29 can be formed on the phosphor 27 . The insulating layer 19 can be interposed between the semiconductor substrate 11 b and the first conductive layer. In addition, the insulating layer 19 can be interposed between the second semiconductor substrate 11 b and the second conductive layer.
[0044] According to the embodiment, a zener diode (not shown) can be formed on the second semiconductor substrate 11 b . The zener diode can be integrated onto the semiconductor substrate 11 b by forming a diode pattern and performing a diffusion process or an ion implantation process for the resultant structure after the insulating layer 19 has been formed, but the embodiment is not limited thereto. As the zener diode is formed, the withstanding voltage of the light emitting device package according to the embodiment can be improved. In addition, according to the embodiment, electronic elements such as a resistor or a capacitor can be integrated into the light emitting device package.
[0045] In the light emitting device package according to the embodiment, a mounting region for the light emitting part 25 is formed in the shape of the two-stage bathtub, so that the light emitting part 25 is mounted on the second surface, which is formed at the bottom of the two-stage bathtub, and the first and second metal layers 21 a and 21 b having high reflectance can be formed on the first surface. Accordingly, light, which is emitted from the light emitting part 25 but cannot be transmitted through a light exit surface (an outer portion of the light emitting device package), is reflected toward the first surface, and light reflected from the first surface is emitted out of the light emitting device package without being incident onto the light emitting part 25 , thereby improving light efficiency.
[0046] In addition, the distance between a reflective surface, such as a (111) surface formed between the first surface and the second surface, and the light emitting part 25 , and the height of the phosphor 27 provided at the upper portion of the light emitting part 25 can be reduced. Accordingly, the light emitted from the light emitting part 25 can be transmitted through the phosphor 27 without causing difference in optical path in all directions around the light emitting part 25 , so that color deviation caused by orientation angles of the light can be reduced, thereby supplying high-quality light.
Second Embodiment
[0047] FIG. 12 is a sectional view showing a light emitting device package according to a second embodiment.
[0048] The light emitting device package according to the second embodiment includes the second semiconductor substrate 11 b , the light emitting part 25 , the first metal layer 21 a , the second metal layer 21 b , the third metal layer 23 a , the fourth metal layer 23 b , a first molding part 31 , a second molding part 32 , and the insulating layer 19 .
[0049] The second embodiment can employ the technical features of the first embodiment, so the second embodiment will be described while focusing on the features distinguished from the first embodiment.
[0050] Different from the first embodiment, according to the second embodiment, a phosphor is provided in the second molding part 32 . For example, the first molding part 31 can be formed on the light emitting part 25 , and the second molding part 32 can be formed on the first molding part 31 . The second molding part 32 can include a second phosphor. The first molding part 31 can be filled with transparent silicon gel. In addition, the first molding part 31 can include a first phosphor.
[0051] According to the second embodiment, since the second molding part 32 can include a phosphor, thereby realizing a remove phosphor structure in which the light emitting part 25 is spaced apart from the second molding part 32 including a phosphor to improve light efficiency.
Third Embodiment
[0052] FIG. 13 is a sectional view showing a light emitting device package according to a third embodiment.
[0053] The third embodiment can employ the technical features of the first embodiment, so that the third embodiment will be described while focusing on the features distinguished from the first embodiment.
[0054] When compared to the first embodiment, the third embodiment employs a third semiconductor substrate 11 c having a first surface in a concave-convex shape. For example, when a second surface of the third semiconductor substrate 11 c is formed, the second surface having the second depth is formed in a second region of the first surface, and a third surface having a concave-convex shape is formed in a third region of the first surface, thereby forming the third semiconductor substrate 11 c having a concave-convex shape as shown in FIG. 13 . The concave-convex shape can include a V-shape groove, but the embodiment is not limited thereto.
[0055] According to the third embodiment, the V-shape groove is formed on the first surface, so that light, which does not escape from the light emitting device package but is reflected toward the first surface, is reflected from a concave-convex surface with a changed reflection angle to increase the probability in which the light is emitted from the light emitting device package. Therefore, light efficiency can be more improved.
Fourth Embodiment
[0056] FIG. 14 is a sectional view showing a light emitting device package according to a fourth embodiment.
[0057] The fourth embodiment can employ the technical features of the second embodiment, so that the fourth embodiment will be described while focusing on the features distinguished from the second embodiment.
[0058] Different from the second embodiment, the first surface of the semiconductor substrate 11 c can have a concave-convex pattern according to the fourth embodiment.
[0059] For example, when the second surface of the semiconductor substrate 11 c is formed, the second surface having the second depth is formed in the second region of the first surface, and a third surface having a concave-convex shape is formed in the third region of the first surface, thereby forming the semiconductor substrate 11 c having a concave-convex pattern as shown in FIG. 14 .
[0060] According to the fourth embodiment, the V-shape groove is formed on the first surface, so that light, which does not escape from the light emitting device package but is reflected toward the first surface, is reflected from a concave-convex surface with a changed reflection angle to increase the probability in which the light is emitted from the light emitting device package. Therefore, light efficiency can be more improved.
[0061] According to the fourth embodiment, the second molding part 32 includes a phosphor, thereby realizing a remove phosphor structure in which the light emitting part 25 is spaced apart from the second molding part 32 including the phosphor, so that light efficiency can be improved.
Fifth Embodiment
[0062] FIG. 15 is a sectional view showing a light emitting device package according to a fifth embodiment.
[0063] The fifth embodiment can employ the technical features of the first embodiment, so that the fifth embodiment will be described while focusing on the features distinguished from the first embodiment.
[0064] According to the fifth embodiment, the light emitting device package includes a semiconductor substrate 40 , a light emitting part 45 , a first metal layer 41 a , a second metal layer 41 b , a third metal layer 43 a , a fourth metal layer 43 b , a phosphor 47 , an insulating layer 39 , and a molding part 49 .
[0065] When comparing with the first embodiment, the fifth embodiment has difference in that first and second via holes 53 a and 53 b are formed in the semiconductor substrate 40 .
[0066] For example, the first metal layer 41 a can be electrically connected to the third metal layer 43 a through the first via hole 53 a formed in the second surface of the semiconductor substrate 40 . In addition, the second metal layer 41 b is electrically connected to the fourth metal layer 43 b through the second vial hole 53 b formed in the second surface of the semiconductor substrate 40 .
[0067] According to the fifth embodiment, when the second surface of the semiconductor substrate 40 is formed, the second surface having the second depth is formed in the second region of the first surface, and the first and second vial holes 53 a and 53 b can be formed in the second surface through the semiconductor substrate 40 .
[0068] A desirable etching mask pattern is formed on the upper and lower surfaces of the semiconductor substrate 40 , and the etching process for the upper and lower surfaces of the semiconductor substrate 40 is performed, thereby realizing the semiconductor substrate 40 including the first and second via holes 53 a and 53 b.
[0069] According to the embodiment, the first conductive layer is electrically connected to the second conductive layer through the first via hole 53 a or the second via hole 53 b , so that a small-scale light emitting device package can be formed.
Sixth Embodiment
[0070] FIG. 16 is a sectional view showing a light emitting device package according to a sixth embodiment.
[0071] The sixth embodiment can employ the technical features of the fifth embodiment, so that the sixth embodiment will be described while focusing on the features distinguished from the fifth embodiment.
[0072] The light emitting device package according to the sixth embodiment can include the semiconductor substrate 40 , the light emitting part 45 , the first metal layer 41 a , the second metal layer 41 b , the third metal layer 43 a , the fourth metal layer 43 b , a first molding part 51 , a second molding part 52 , and the insulating layer 39 .
[0073] When compared to the fifth embodiment, the sixth embodiment can employ the second molding part 52 having a phosphor. For example, the first molding part 51 can be formed on the light emitting part 45 , and the second molding part 52 can be formed on the first molding part 51 . The second molding part 52 can include the second phosphor. The first molding part 51 can be filled with transparent silicon gel, but the embodiment is not limited thereto. In addition, the first molding part 31 can include the first phosphor.
[0074] According to the sixth embodiment, the second molding part 32 includes a phosphor, thereby realizing a remove phosphor structure in which the light emitting part 45 is spaced apart from the second molding part 32 including the phosphor, so that light efficiency can be improved.
[0075] According to the sixth embodiment, the first conductive layer can be electrically connected to the second conductive layer through the first via hole 53 a or the second via hole 53 b , so that a small-scale light emitting device package can be formed.
Seventh Embodiment
[0076] FIG. 17 is a sectional view showing a light emitting device package according to a seventh embodiment.
[0077] The seventh embodiment can employ the technical features of the fifth embodiment, so that the seventh embodiment will be described while focusing on the features distinguished from the fifth embodiment.
[0078] When compared to the fifth embodiment, the seventh embodiment can employ the semiconductor substrate 40 having the first surface in a concave-convex shape.
[0079] When the second surface of the semiconductor substrate 40 is formed, the second surface having the second depth can be formed in the second region of the first surface, and the third surface having a concave-convex shape can be formed in the third region of the first surface, so that the semiconductor substrate 40 having a concave-convex shape can be formed.
[0080] According to the seventh embodiment, the V-shape groove can be formed in the first surface, so that light, which does not escape from the light emitting device package but is reflected toward the first surface, can be reflected from the concave-convex surface with a changed reflection angle to increase the probability in which the light is emitted from the light emitting device package. Therefore, light efficiency can be more improved.
Eighth Embodiment
[0081] FIG. 18 is a sectional view showing a light emitting device package according to an eighth embodiment.
[0082] The eighth embodiment can employ the technical features of the sixth embodiment, so that the eighth embodiment will be described while focusing on the features distinguished from the sixth embodiment will be mainly described.
[0083] When compared to the sixth embodiment, the eighth embodiment can employ the semiconductor substrate 40 having the first surface in the concave-convex shape.
[0084] When the second surface of the semiconductor substrate 40 is formed, the second surface having the second depth can be formed in the second region of the first surface, and the third surface having a concave-convex shape can be formed in the third region of the first surface, so that the semiconductor substrate 40 having a concave-convex shape can be formed.
[0085] According to the eighth embodiment, the V-shape groove can be formed in the first surface, so that light, which does not escape from the light emitting device package but is reflected toward the first surface, can be reflected from the concave-convex surface with a changed reflection angle to increase the probability in which the light is emitted from the light emitting device package. Therefore, light efficiency can be more improved.
[0086] According to the eighth embodiment, the second molding part 52 can include a phosphor, thereby realizing a remove phosphor structure in which the light emitting part 45 is spaced apart from the second molding part 52 including the phosphor, so that light efficiency can be improved.
[0087] As described above, in the light emitting device package according to the embodiments, the light efficiency can be improved, and the color deviation can be reduced.
[0088] Any reference in this specification to “one embodiment,” “an embodiment,” “example embodiment,” etc., means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with any embodiment, it is submitted that it is within the purview of one skilled in the art to effect such feature, structure, or characteristic in connection with other ones of the embodiments.
[0089] Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art. | Disclosed is a light emitting device package. The light emitting device package includes a substrate comprising a recess, a light emitting chip on the substrate and a first conductive layer electrically connected to the light emitting chip. And the first conductive layer includes at least one metal layer electrically connected to the light emitting chip on an outer circumference of the substrate. | 7 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to plastic packing elements of the type that are often called “random” or “dumped” packings. Such packings are used to fill towers units in which mass or heat transfer processes occur. The objective of the packings is to provide maximum effective contact between fluids flowing in the tower. Maximum efficiency is achieved when liquid flows down the tower in thin films or small droplets rather than in streams. Another key factor in maximizing efficiency is the maintenance of as low a pressure difference between top and bottom of the tower as possible. To ensure this the packing elements should present the minimum resistance to flow. This is promoted by very open structures but open structure alone is of limited use if the elements in the tower nest together such that parts of one packing element penetrate within the space of a second element. It is therefore important that the design of the elements minimize the tendency of the elements to nest together.
[0002] A novel design for a packing element has now been found that provides greater than 95% of open space within the element and still resists nesting of the elements which reduces the open space and promotes uniform flow and turbulent mixing of fluids within a tower filled with the packings.
[0003] The design has the advantage that the packing can, if desired, be molded from a flat plastic sheet or injection-molded in a simple operation to produce a very open shape that resists crushing and nesting.
DESCRIPTION OF THE INVENTION
[0004] The present invention provides a plastic packing element in the form of a basic plastic sheet located in a first plane and having the form of a polygon with 3 to 6 corners from which a first group of spaced peripheral strips between each pair of adjacent corners of the sheet are deformed in a first direction to form a first set of arched structures with the apices of at least some of the arches in a second plane parallel to the first plane and removed therefrom in the first direction, a second group of strips equal in number and parallel to the corresponding strips in the first group but each being displaced radially inwardly from the corresponding strip from the first group, each strip being deformed out of the first plane in a second direction which is generally opposite to the first direction to form a second set of arched structures with the apices at least some of the arches in a third plane parallel to the first plane, and an axially central aperture formed in the sheet and defined by a generally circular periphery and an axially-located rod connected to the periphery by a plurality of radial struts.
[0005] Both sets of arches can be described as extending generally above or below the first plane but the plane of each arch need not be perpendicular to the first plane and indeed it is often preferred that this is not so. For this reason the direction of deformation of the inner set of strips to form the secon set of arched structures is described as being “generally opposite” from the first direction in which the outer set of strips were deformed to form the first set of arched structures. This is intended however only to require that the apices of the two groups of arches lie on different sides of the first plane.
[0006] The basic sheet upon which the packing element is constructed is preferably axially symmetrical with sides of equal length. The preferred number of equal length sides is three.
[0007] In a preferred structure the lengths of each of the second group of parallel strips from which the second set of arched structures are formed are shorter than the corresponding adjacent strips from the first group of strips. Thus the arched structures formed from the second set of strips are preferably smaller than those formed from the first set of strips. It is also preferred that the arched structures within each group be substantially the same size such the apices of all arched structures within a group lie in the same plane parallel to and displaced from the first plane.
[0008] The axially located aperture is defined by a periphery and is preferably provided with tongue members which project from the periphery in the first direction.
[0009] Apertures defined by a generally circular periphery are also preferably located adjacent at least some of the corners of the polygonal sheet. These also are provided with tongues dependent in the first direction from the periphery of the corner apertures.
[0010] The tongues depending in the first direction from the periphery of both the axial and corner apertures preferably have the shape of triangles and most preferably the triangles are equilateral or have two equal sides with the shortest side at the periphery of the aperture.
[0011] The tongues not only provide excellent means of breaking up stream flows into a series of drips but they also generate turbulence in gas flows passing therethrough, so enhancing the efficiency of the contact between counterflowing fluids.
[0012] The shapes described herein are particularly effective because they have greater than 95% internal open space ensuring a very low pressure drop while at the same time resisting nesting and deformation under pressure.
[0013] The invention further comprises a process for the production of a packing element according to the invention which comprises providing a polygonal plastic sheet having from 3 to 6 corners and symmetrical about an axis perpendicular to the sheet:
[0014] a) incising a first group of cut lines, each of which is adjacent to, parallel to and equidistant from one of the sides of the sheet to form a first group of strips between each pair of adjacent corners of the sheet and each located between an edge of the sheet and a cut line;
[0015] b) incising a second group of cut lines, each line being adjacent to, parallel to, and equidistant from one of the lines of the first group of cut lines to form a second group of strips parallel to the first;
[0016] c) incising a group of cut lines of equal length radiating from the axis of the sheet;
[0017] and then applying pressure to the sheet to deform the sides of the sheet between the edges and the first cut lines in a first direction to form a first set of arched structures; deforming the strips between the first and second cut lines in a generally diametrically opposite direction to said first direction to form a second set of arched structures, and bending the portions of the sheet between adjacent lines of those cut radially from the axis of the sheet so as to form a plurality of dependent tongues projecting in the first direction from the periphery of an aperture in the sheet.
[0018] In a preferred process each of the corners of the polygonal sheet is provided with a pattern of cut lines of equal length radiating from a point adjacent each corner and the portions of the sheet between adjacent radial cut lines is bent in the first direction such that an aperture is formed with a circle of triangular tongues depending in the first direction from the periphery of the aperture.
[0019] In a further preferred process the plastic packing according to the invention is made by an injection molding process. Packing elements made by such a process are preferably provided with strengthening ribs that would not be readily provided if the element were to be made by deformation from a flat sheet as described above. Thus it is particularly preferred that the arched structures extending between the same pairs of corners of the sheet are connected by a plurality of parallel ribs. A further preferred feature of injection molded packing elements is a network of ribs connecting the periphery of the central aperture with the corners of the sheet and with the arched structures.
DRAWINGS
[0020] [0020]FIG. 1 is a perspective view of a packing element of the invention from a point below and to one side, looking directly at one of the corners of the triangular element.
[0021] [0021]FIG. 2 shows the same element as is shown in FIG. 1 from the side, this time looking directly at the mid-point of one of the sides of the element.
[0022] [0022]FIG. 3 is a view looking down on the element depicted in FIGS. 1 and 2.
DESCRIPTION OF PREFERRED EMBODIMENT
[0023] The invention is now more particularly described with reference to the embodiment illustrated in the Drawings. This is not intended to imply any necessary limitations in the scope of the invention because it will be readily appreciated that many minor variations could be made without departing from the essential spirit of the invention.
[0024] The Drawings show a triangular packing element, 1 , with three corners, 2 . Along each of the three edges of the sheet first arched structures, 3 , extend generally downwards, each structure being of essentially the same dimensions. Located inwardly of the set of first arched structures, 3 , is a second set of arched structures, 4 , formed in a direction that is generally diametrically opposite to that of the first set of arched structures. The axially central portion of the element is provided with a generally circular aperture, 6 , from the periphery of which tongues, 7 depend in the first direction. Circular apertures, 8 , are provided adjacent each of the corners of the element, each being provided with septa, 11 , extending across diameters of the aperture.
[0025] The apices of each of the arched structures in each group lie in the same plane, though it is noted that the structures extending in the second direction are smaller than those extending in the first direction.
[0026] Axially located in the center of the central aperture is a rod, 9 , from which radially extending ribs, 10 , connect the rod to the periphery of the aperture, the corners of the element, and to the mid-points of parallel connecting struts, 12 , extending between each pair of first and second arched structures between adjacent corners of the element. | The invention provides a novel improved plastic packing element having the basic shape of a polygon with arches formed around the periphery by deforming the edge area in one direction and an area axially within the edge area to form arches projecting in the opposite direction and providing an axially located aperture. Such packing elements can be conveniently formed using a simple cutting and stamping operation or, more preferably, by an injection molding process. | 1 |
BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
The invention relates to a method and apparatus for mass spectrometric analysis, and in particular to an apparatus for and a method of spectrometrically analyzing a sample mass that is ionized by a laser beam.
2. DESCRIPTION OF RELATED ART
In one type of conventional mass spectrometric analyzing apparatus, the sample is ionized by an atmospheric ionizing method. For example, the sample is ionized by a glow discharge method. This type of apparatus, however, is restricted in use to ionizing gaseous samples, and is consequently disadvantageous for use in analyzing a wide variety of samples.
An example of a mass spectroscope that uses a laser for ionizing the sample portion is disclosed in the Proceedings of the 23rd Applied Spectrometry in Tokyo, 1988, at 135, 137. In this type of apparatus, a sample is irradiated with a laser beam for ionization, and only the surface of the solid is irradiated. This causes simple ionization of the surface molecules, or generates ions by sputtering. Laser breakdown, which will be described later, is not produced because the power density of the laser beam is low. Therefore, the apparatus is restricted to analyzing the surface of a solid.
In Japanese Patent Publication No. 46340/1983, a method of separating isotopes by irradiating a target with a laser beam for ionization and spectrum analysis of the mass of the ions is disclosed. The object of this method is to separate the isotopes. A laser beam of a very high intensity is used to ionize the target. A plasma is produced, and the ions generated are in a charged state that is greater than ten times as high as the charged state of a single electron. As a result, the same element of the sample in the plasma that is produced has not fewer than ten different charged states. Accordingly, the Z/m (Z being the ion charge, and m the mass) is different for each of the charged states of the same element. If the isotopes are separated by a mass spectrometer, then the same elements are collected by separate depositors (isotope collectors). The target material composition is analyzed with high sensitivity if the same elements are collected by the same depositor of the mass spectrometer. However, in this example, the same elements are collected by separate depositors depending upon the charged states, and different elements having the same Z/m value are collected by the same depositor. As a result, this type of ionizing apparatus is not appropriate for the separation and quantitative determination of only the mass m which is necessary for the analysis of a material composition.
In Japanese Patent Laid-Open No. 78384/1975, a mass spectrometric analysis of particles in an explosive plasma that is produced by laser fusion is disclosed. In this apparatus, the charged particles have the same Z/m value and different initial speeds are introduced to the same detector by utilizing a time-dependence type charged particle separating magnetic field in order to measure the mass and the charge of the particles with high sensitivity. The plasma described in this example is plasma having a high temperature and a high density produced by laser irradiation for nuclear fusion. Since the intensity of the laser beam is high, the ion charges are also high. Accordingly, the same elements have different charged states and this type of ionizing method is unsuitable for the analysis of ordinary material compositions.
In West German Patent Laid-Open No. 252010, a method of spectrometrically analyzing the mass of the ions of a plasma that is produced by a laser deposition apparatus is disclosed. The laser deposition apparatus irradiates the material for the substance to be deposited on a substrate with a laser beam to evaporate the substance in the form of atoms or molecules. Part of the evaporated atoms or molecules are ionized by the irradiation of the laser beam. These ions, atoms or particles ordinarily collide with the ions, atoms or particles therearound and form minute clusters. The clusters having charges or ions are taken out by an electrode and introduced onto the substrate. The clusters or ions adhere to the substrate, thereby forming a thin film. Generally, the evaporated gas contains neutral atoms, particles, and the clusters and ions thereof. In order to observe the mass and the charge of the evaporated substance, therefore, the ion components are introduced to the mass spectrometer so as to spectrometrically analyze them. In the analysis, the evaporated atoms, molecules and ions generated during evaporation and the ion components in the clusters are utilized. This mass spectrometric analysis is different from a mass spectrometric analysis in which a material is positively and efficiently evaporated in the form of atoms and ionized for the purpose of elemental analysis (to determine atomic composition) of the material.
The conventional apparatus, described above, for ionizing samples using a laser beam for various purposes is unsuitable for mass spectrometric analysis intended for the analysis of a material composition. That is, even if a conventional laser apparatus is used in the field of mass spectrometric analysis, the ions generated by the laser beam irradiation are not in a predominantly low charged state, and therefore, are not suitable for mass spectrometric analysis.
In addition, when particle components in a liquid or a solid are analyzed, selective and efficient ionization of the particle components is not taken into adequate consideration in the practice of analysis with conventional apparatus. Therefore, it is difficult to analyze a material of various forms such as solids, liquids, and gases for elemental constituents with high sensitivity.
An analysis apparatus that uses a laser beam for laser breakdown of the sample is known. In such an analyzing method using laser breakdown, fine particles in the liquid are counted by using a sound wave generator, as described in, for example, Japanese Journal of Applied Physics, 1988, 27, at L983. Alternatively, it is known to analyze a liquid for elemental constituents by spectrum analysis of a plasma emission produced by laser breakdown, as described in Applied Spectroscopy, 1984, 38, at 721. That is, mass spectrometric analysis using ions generated by the laser breakdown of a sample is not carried out in these type of apparatus.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method and apparatus for the mass spectrometric analysis of samples in gaseous, liquid and solid states.
It is an object of the present invention to spectrometrically analyze a mass by producing predominantly monovalent or low valent ions with high efficiency that are suitable for mass spectrometric analysis.
It is a further object of the present invention to spectrometrically analyze a mass with high sensitivity by selectively ionizing a sample in a solid, liquid or gaseous state or by ionizing a solid substance (particulate substance) sample contained in a liquid or gas.
It is an object of the present invention to spectrometrically analyze the mass of ions generated by momentary ionization with an apparatus that is efficient in size and simple in operation.
In the present invention, a sample object is ionized by breaking down (a kind of insulation breakdown) a part or the entire part of the sample object by irradiating the sample with a laser beam, preferably a pulse laser beam generated by a pulse laser. The power density of the laser beam is adjusted so that the ions generated by the breakdown of the sample have a low charge. The adjustment is made so that the power density of the laser beam is not only higher than the threshold value for the breakdown of the sample, but also near the threshold value.
After the momentary breakdown of the object of analysis or sample into the form of a plasma by irradiating the sample with a pulse laser beam, and after a certain time has elapsed since the plasma is formed wherein the ions generated with a high charge are recombined with the ionized electrons to produce monovalent or low valent ions, the ions are taken out of the plasma and introduced to an apparatus for the mass spectrometric analysis thereof.
Selective breaking down of a solid, liquid or gaseous sample, and of a particulate substance contained in a liquid or gas can be accomplished by adjusting the power density of the laser beam to the threshold value of the sample. There is a difference in threshold value of the power density of the laser beam that is necessary for breaking down liquids, gases, solids and particulate substances contained in a liquid or gas. Therefore, samples in various physical states can be analyzed by mass spectrometric analysis with the apparatus of the present invention, and according to the method of the present invention.
The pulse laser beam is used to break down an object of analysis or sample into the form of a plasma by a thermal, optical and electric effect of the laser beam. This phenomenon is called laser breakdown, and is achieved when the power density of the laser beam is not less than 10 10 W/cm 2 . The power density is adjusted by condensing the laser beam with a convex lens, or the like. In the plasma produced by the laser breakdown, ions and electrons are contained in a mixed state. The ions that are generated recombine with the electrons in the plasma to form neutral atoms. Before the recombination, the ions are taken out for mass spectrometric analysis.
With reference to FIGS. 13(a) and 13(b), an example of a plasma emission spectrum obtained by spectrometrically measuring a temporal variation of a plasma emission generated when a pulse laser is used to irradiate a solution sample for breaking it down into the form of a plasma is shown. Although the plasma emission spectrum shown in each of the figures is the same, FIG. 13(b) shows the plasma emission spectrum diagram with the ordinate magnified ten times. The solution sample is an aqueous Na solution. According to the results shown in the figures, the plasma emission continues for about 5 to 6 μseconds. It is sufficiently possible to take out the ions for the mass spectrometric analysis during this period. White light from the plasma is observed immediately after the breakdown and thereafter the Na atom emission lines (D-lines having wavelengths of 589.0 nm and 589.6 nm) are distinctly observed. Immediately after the breakdown of the solution, Na is converted into monovalent or low valent ions and can assume various excited states, so that light of various wavelengths is emitted in accordance with the exciting state. As a result, white light is observed. As time elapses after the breakdown, the polyvalent ions combine with the electrons, thereby producing monovalent Na ions. When electrons recombine with the monovalent Na ions to produce neutral Na atoms, the combined electrons change the state into the ground state, thereby emitting the Na atoms emission lines (D-lines).
In FIG. 13(b), the magnified ordinate of the spectrum diagram shows that the atom emission lines are distinctly observed after elapse of about 300 ns, which indicates that a multiplicity of monovalent Na ions have been generated during the process of extinguishing the plasma. It is considered from the strong Na atom emission lines that are observed after about 300 ns have passed, that a multiplicity of monovalent Na ions have been generated in this period, and it is further considered that a multiplicity of monovalent or divalent ions have been generated in the breakdown plasma.
If an electromagnetic force, for example, is applied to the plasma when the atom emission line begins to be observed after the generation of the breakdown plasma, it is possible to take out the monovalent ions with high efficiency.
The power density of the laser beam that is necessary for breaking down a substance or sample is different for solids, liquids and gases. When the power density of the beam is in the order of 10 10 W/cm 2 , the breakdown of a solid is produced. When the power density is in the order of 10 11 W/cm 2 , the breakdown of a liquid is produced. Further, when the power density of the laser beam is in the order of 10 12 W/cm 2 , the breakdown of a gas is produced. These power level densities are described in U.S. patent application Ser. No. 07/334,358, entitled "Analytical Method for Particulate Substances, Relevant Analytical Equipment and its Application System".
In view of the differing power density levels for solids, liquids and gases, it is possible to selectively break down and ionize a sample or object of analysis by appropriately setting the power density of the beam in accordance with the form or state of the sample. Since the power density for breaking down a solid is less than that for a liquid, it is possible to break down a solid particulate substance in a liquid medium without breaking down the liquid medium. Similarly, it is possible to selectively ionize a particulate substance in a gaseous medium without breaking down the gaseous medium. Further, with the apparatus of the present invention, it is possible to ionize a substance by laser breakdown whether the substance is a conductor, semiconductor or insulator. Therefore, it is possible to ionize and then analyze a wide range of substances, such as solids, including metals and oxides in a gas or liquid medium, as well as gases and liquids themselves.
Ionization is caused by irradiating the sample with a laser beam. In order to obtain the power density of the laser beam that is necessary for the laser breakdown, the laser is preferably subjected to pulse oscillation. In order to analyze the ions that are generated, a time-of-flight mass spectrometric analyzing method that is capable of being actuated synchronously with the pulse oscillation of the laser beam is preferably used. In this preferred system, the pulse laser beam irradiates the object of analysis or sample for breaking it down, and the ions in the plasma produced are taken out by, for example, an electrode with a voltage applied thereto and introduced into the time-of-flight mass spectrometer. If it is assumed that the voltage applied to the electrode is V, the mass m and the velocity v of the ions having a charge (valence) of q are obtained according to the following equation:
1/2mv.sup.2 =qV (1)
Therefore, in the time-of-flight mass spectrometer for a distance L of flight, the time T of flight of the ions is represented by the following formula: ##EQU1## Rearranging formula (2), the following formula is obtained: ##EQU2##
It is therefore possible to obtain the m/q of the ions from the formula (2) by measuring the period T between the time of the production of the breakdown and the time of the detection of the ions. In particular, when the ions are monovalent (q=e, wherein e represents a charge of an electron), T and m have a relationship of 1 : 1, so that by measuring the time T of flight, it is possible to obtain the mass m of the ions, thereby identifying the element. The measurement starting time for the time T of flight can be the oscillating time of the pulse laser, the time at which the pulse laser beam is observed, the time at which the plasma emission is observed or a predetermined time after these times are set. Further, as for the timing of applying a voltage to the electrode for taking out the ions from the plasma, the time at which the atom emission lines or the monovalent or low valent ion emission lines are observed in the plasma emission, or the like, may be utilized.
BRIEF SUMMARY OF THE DRAWING
Further objects, features and advantages of the present invention will become clear from the following Detailed Description of the Preferred Embodiments, as shown in the accompanying drawing, wherein:
FIGS. 1 and 2 are views of first and second embodiments of the invention, respectively;
FIG. 3 is a view of the sample container and vacuum chamber system for the apparatus of the invention shown in FIGS. 1 and 2;
FIG. 4 is a view of a breakdown chamber constructed according to the present invention for a gaseous sample;
FIG. 5 is a view of a breakdown chamber constructed according to the present invention for a liquid sample;
FIGS. 6 to 9 are views of a breakdown chamber constructed according to the present invention for a solid sample;
FIGS. 10 and 11 are views of a time-of-flight mass spectrometer used in the present invention;
FIG. 12 is a view of a breakdown chamber for a liquid sample constructed according to another embodiment of the invention;
FIGS. 13(a) and 13(b) are diagrams of a breakdown plasma emission spectrum of a Na solution sample; and
FIG. 14 is a diagram showing the mass spectrum of a particulate substance in air.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, the fundamental structure of the present invention is shown. A laser 1 emits a laser beam 13 having a wavelength of 1064 nm, a pulse width of 10 ns and an output of 100 mJ. Preferably, the laser is a pulsed YAg laser (Yttrium-Aluminum-garnet laser). The laser beam 13 is condensed by a condenser lens 2 and enters a gas breakdown chamber 3. The laser beam 13 focuses within the breakdown chamber 3 and induces the laser breakdown of the gas in the vicinity of the focal point of the beam. The laser beam 13 passes through the breakdown chamber 3 and is absorbed by a beam stopper 12.
The gaseous sample to be ionized by the laser beam is introduced to the breakdown chamber 3 through a sample passage 4 and discharged. The constituent atoms of the gaseous sample that are converted into a plasma by the laser breakdown and ionized in the breakdown chamber 3 are accelerated by an accelerating electrode 5 through a slit in the breakdown chamber. The ions pass through slit 5 and are introduced to an ion deflector 6 of a time-of-flight mass spectrometer (hereinafter referred to as "TOF"). The ion detector 6 is actuated synchronously with the laser 1 and introduces the ions 80 generated by the laser breakdown to an ion collector 7. An ion current 11 from the ion collector 7 is processed to obtain the time-of-flight mass spectrum (hereinafter referred to as "TOF spectrum") on the basis of the time at which the ion deflector 6 has been actuated. A pulse generator 8 generates a control signal 10 for actuating laser 1, the ion deflector 6 and the signal processor 9 synchronously with each other.
In FIG. 2, another embodiment of the present invention is shown. This second embodiment of the invention differs from the first in that a signal delay controller 31, a voltage applier 32 and an ion take-out electrode 33 are provided. The signal delay controller 31 actuates the voltage applier 32 at a preset time after the time at which a pulse signal is generated so as to apply a voltage to the ion take-out electrode 33. Then, it is accelerated by the accelerating electrode 5 and introduced to the ion deflector 6 of the TOF.
Accordingly, it is possible to spectrometrically analyze the mass of the sample by taking out the ions in the plasma at a preset time after the sample is broken down into the form of a plasma. Preferably, the plasma emission is spectrometrically measured by a device 81. The output of the measurement device 81 is input to the signal processor 9, and it is determined whether or not the intensity of the atom emission lines or the monovalent ion emission lines exceed a preset value. When the preset value is exceeded, then the low valent ions including the monovalent ions are extracted for spectrometric analysis.
FIG. 3 shows a preferred chamber system for containing the plasma and taking out the ions. The sample is contained in ionizing portion 14, which is a breakdown chamber maintained at atmospheric pressure. A differential evacuating portion 15 houses the accelerating electrode 5, for example, and is evacuated to a pressure of 10 -1 Pa by a turbo molecular pump 17. A further chamber 16 houses the mass spectrometer, for example, and is evacuated to 10 -3 Pa by another turbo molecular pump 17. Therefore, with this preferred arrangement, the ions generated under atmospheric pressure are introduced into the high vacuum chambers.
The breakdown chamber 3, shown in the embodiments of the invention in FIGS. 1 and 2, is able to contain gaseous, liquid and solid samples. Breakdown chamber 3 is shown in greater detail in FIG. 4. A gaseous sample is introduced into the breakdown chamber 3 through the sample passage 4. The laser beam 13 is condensed by a condenser lens 2, radiated into the breakdown chamber through an aperture 18 disposed at the top of the chamber, and is absorbed by a beam stopper 12 disposed outside of the chamber after passing through an aperture 18'. The power density of the laser beam is adjusted to exceed the breakdown threshold value of the sample in the vicinity of the focal point, and therefore the gaseous sample is ionized by the laser breakdown. When the sample is a particulate substance suspended in a gas, only the particulate substance is broken down and the gas medium is not ionized. For example, if the power density of the laser beam is set at a value of not less than 10 12 W/cm 2 , the gaseous sample is broken down and ionized. If the power beam density is set at a value of 10 10 to 10 11 W/cm 2 , only the particulate substance in the gas is broken down. On the other hand, if the power density of the laser beam is set at a value of 10 11 to 10 12 W/cm 2 , only the particulate or liquid substance suspended in the gas is broken down, thereby enabling the analysis of a substance in the form of a droplet.
When a liquid sample is to be analyzed, preferably a breakdown chamber 20, as shown in FIG. 5, is used. The breakdown chamber 20 is of a conical shape, and the liquid is introduced into the chamber through a sample pipe 19. The top surface of the conical breakdown chamber 20 has an aperture 21, and the lower portion of the breakdown chamber 20 is narrowed to form a narrow hole 27. The liquid sample is discharged from a sample discharge pipe 22 in the form of a very fine stream through the narrow hole. The laser beam 13 is condensed by the condenser lens 2 and is introduced to the breakdown chamber 20 through aperture 21. The laser beam is condensed along the inner wall surface of the conical breakdown chamber 20 and focuses at the point at which the laser beam passes through the narrow hole to outside of the breakdown chamber 20. Therefore, the laser beam focuses midway of the narrow stream just inside the narrow hole 27 at the lower portion of the chamber, thereby inducing a breakdown of the sample. In this way, the liquid sample is ionized in air by laser breakdown. In operation, if the power density of the laser beam at the focal point is set at a value of not less than 10 11 W/cm 2 , the liquid sample can be broken down and ionized, thereby enabling the analysis of the liquid for elemental constituents. If the power density of the laser beam at the focal point is set at 10 10 W/cm 2 , only the particulate substance in the liquid will be broken down and ionized, thereby enabling an analysis of a particulate substance suspended in the liquid.
In FIG. 5, the laser beam is focused on a portion of a narrow stream of the liquid that has emerged from narrow hole 27 at the lower portion of the breakdown chamber 20. Alternatively, the liquid sample may be broken down by focusing the laser beam on a droplet of the liquid sample that has emerged from the narrow hole 27 at the lower portion of the chamber. It is also possible to break down the liquid by radiating the laser beam in the horizontal direction such that it focuses on the narrow stream or on a droplet of the liquid sample at a predetermined location within the chamber.
In the case of analyzing a solid sample, a breakdown chamber 26 is preferably used, as shown in FIG. 6. The laser beam 13 is condensed by the condenser lens 2 and a focal lens 25 is provided in an upper portion of the breakdown chamber 26. The solid sample 24 is fixed on a sample table 23 disposed in a lower portion of the breakdown chamber 26. The power density of the laser beam is adjusted to be 10 9 to 10 11 W/cm 2 , and a plasma is formed.
Another embodiment of a breakdown chamber for a solid sample is shown in FIG. 7. In this embodiment, a sample table driving and controlling device 44 is provided to enable the laser beam to be irradiated onto a given portion of a sample 24 by moving the sample table 23.
In FIG. 8, a driving and controlling device 44 is shown for moving the condenser lens 2 to thereby control the position and the direction of the laser beam. In this way, scanning of the sample with the laser beam in the breakdown chamber can be performed.
In FIG. 9, another embodiment of the present invention is shown that includes a driving and controlling device 46 for moving a condenser lens system 43 to enable positioning of the laser beam and to enable scanning irradiation of the object being analyzed.
In FIGS. 7 to 9, a signal relating to the position of the sample table and an output from the respectively disclosed driving and controlling device are supplied to signal processor 9, shown in FIGS. 1 and 2. The signal processor 9 calculates and stores the position of the laser beam on the sample surface, according to movement of the sample table 23 by driving and controlling device 44; the condenser lens 22 by driving and controlling device 45; and the condenser lens system 43 by driving and controlling device 46, respectively.
FIG. 10 shows an example of a time-of-flight mass spectrometer. The ions generated by the breakdown are taken out by an ion take-out electrode 52 disposed in an ion flight tube 51. The ions enter the ion flight tube 51 through the entrance 51a provided at one end of the tube 51. The direction of progress of the ions is deviated by a minute angle influenced by an ion deflector 53 so that the path of flight of the ions is separated from the path of flight of the neutral atoms. Then, the number of ions are measured by an ion detector 54. The time required for the ions to reach the ion detector 54 after passing the ion take-out electrode 52 differs in proportion to the mass of the ions. It is therefore possible to determine the mass of the ions from the time difference of the detection signal of the ion detector 54 and to obtain the number of ions from the intensity of the detecting signal. A neutral atom is not influenced by the ion deflector 53 and enters an atom detector 55. The total number of atoms is obtained from the detection signal of the atom detector 55. Preferably, the ion flight tube is evacuated to a low pressure by molecular turbo pumps 56 and 57.
FIG. 11 shows another example of a time-of-flight mass spectrometer, wherein the ion flight tube 51 is further provided with the electrodes 61, 63 and 64, as well as electrodes 52 and 53. A voltage controller 62 is provided for the electrode 61. The ions taken out of the breakdown chamber pass through electrode 52 and are deflected by an ion deflector 53, as in the TOF shown in FIG. 10. The ions pass through the midportion of the tube 51 and are influenced by an electrode 63. Then, the ions are repelled by electrode 64 and are reversed in direction. Traveling in the reversed direction through the midportion of the tube, the ions are again deflected by electrode 63. Then, voltage controller 62 changes the potential of the electrode 61 whereupon the ions reverse direction again. The ions, having been twice reversed in direction, now proceed to the ion detector 54, which measures the ion current so as to obtain the number of ions. This system is advantageous in that the distance of flight of the ions is lengthened, and the time difference in flight between the different ions increases so that resolution of the mass is enhanced, and it is possible to make the ion flight tube smaller in length.
FIG. 12 shows another embodiment of a breakdown chamber and method of breaking down and ionizing a liquid. A liquid sample is contained in a liquid container 70 that is funnel-shaped and provided with a small hole 70a formed at the tip of the funnel. The liquid sample emerges from liquid container 70 through the small hole 70a at the lower portion of the container in the form of a fine line or a droplet. The fine line or droplet passes through a gap provided between a pair of opposing electrodes 71. A power source 72 is actuated in accordance with a control signal derived from a voltage application controller 73 that applies a high voltage to the electrodes 71 in a pulse-like manner. The voltage applied to the electrodes 21 is set at a value above the dielectric breakdown threshold voltage (about 10 6 V/cm).
FIG. 14 shows a TOF spectrum of a particulate substance in a gas measured in accordance with an embodiment of the present invention wherein the particulate substance was ionized by a laser beam. In the TOF spectrum, the peaks of Si having a mass of 28, and 0 having a mass of 16 are mainly detected and it is observed that the main constituent of the particulate substance is SiO x . The peak having a mass of 44 is identified to be the peak of SiO - and the peak having a mass of 60 is identified to be the peak of SiO 2 - .
In accordance with the present invention, it is possible to ionize and analyze a sample in any form or state, such as a gaseous state, liquid state or solid state. Further, it is possible to selectively ionize and analyze a particulate substance suspended in a gas or a liquid. The sample can be of various types, such as an insulator, semiconductor or conductor, as well as a metal or an oxide. Even a substance having a high ionization potential is able to be broken down by the apparatus of the invention for analysis.
In particular, the apparatus of the invention generates monovalent or low valent ions with efficiency by breakdown, thereby enabling analysis of the substance with high sensitivity. Therefore, even trace element constituents of a substance suspended in a gas or liquid can be analyzed.
According to the present invention, it is possible to analyze a substance for elements or molecules by varying the power density of the laser beam used in irradiating the sample. Furthermore, the element constituent analysis is enabled with high sensitivity by an efficiently sized apparatus that combines laser breakdown of the sample with time-of-flight mass spectrometry.
While a preferred embodiment of the invention has been described with variations, further embodiments, variations and modifications are contemplated within the spirit and scope of the follow claims. | The power density of a pulsed laser beam for irradiating a sample is adjusted to break down the sample into the form of a plasma. After the momentary breakdown of the sample into the form of a plasma, ions are generated having a high charge. Then, after a certain time elapses, the ions having a high charge recombine with the electrons in the plasma to provide monovalent or low valent ions. These low valent ions are taken out of the plasma and introduced to a mass spectrometric apparatus. | 7 |
This is a division, of application Ser. No. 870,551, filed Jan. 18, 1978 and now U.S. Pat. No. 4,245,744.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to disposable wet packaged skin cleansing fabrics or cloths formed of paper or other non-woven fibrous webs of the kinds generally known in the art as towelettes, wet-wipes, fem-wipes and the like. It is particularly concerned with the provision of such fabrics which will retain suitable wet tensile strength during storage and use but which can be readily disposed of by flushing in water without danger of clogging the plumbing system.
2. Prior Art
Wet-packaged skin cleansing and refreshing tissues are well known commercially, generally referred to as towelettes, wet-wipes, fem-wipes, and the like. Typical examples of such products are described in U.S. Pat. Nos. 3,057,467; 3,563,371; and 3,398,826. These may comprise an absorbent sheet made of paper, prepared or treated to impart wet strength thereto, having the dimensions of the usual wash cloth and packaged wet in folded condition individually in impervious envelopes or in multiples in closed containers. The liquid employed in pre-moistening the sheet is generally an aqueous alcoholic solution which may further contain a surface-active detergent and humectant and in some instances also a scenting agent. Instead of individual packaging of such moist sheets, these are often marketed in recloseable containers having any desired convenient numbers of such folded sheets. A typical example of such products particularly designed for use in feminine hygiene, popularly known as "fem-wipes," is disclosed in U.S. Pat. No. 2,999,265.
Certain of the earlier known products suffer from the drawbacks of excessive loss of wet strength on account of being kept moist for even relatively short periods of storage, thereby interfering with their intended use by the consumer. Others of these known products which retain adequate wet strength, cannot be readily disposed of by flushing in water in conventional toilet bowls, since the binders employed in imparting wet strength do not disintegrate sufficiently and thus often cause clogging of the plumbing. In some instances it has been advocated that acidic or alkaline materials respectively be added to the water employed in flushing the used cloths to assist in disintegrating the binder therein, these being selected in accordance with the nature of the resinous binder employed.
Polyvinyl alcohols (PVOH) are well known in commerce for use in textile and paper sizing and coating, as adhesives, binding agents, dispersing/stabilizing agents for emulsions, and the like. These alcohols are generally manufactured by polymerizing vinyl acetate and hydrolyzing the polymer to an alcohol. The marketed grades of polyvinyl alcohol vary in degree of polymerization and degree of hydrolysis. As used herein, "fully hydrolyzed" products are those which have been hydrolyzed to about 95% or higher and up to about 99% by weight. Polyvinyl alochols having a degree of hydrolysis above 99% are designated as "super hydrolyzed." Films produced from polyvinyl alcohol grades being a degree of hydrolysis above about 95% are resistant to attack by cold water; the extent of water resistance increasing directly with increase in the degree of hydrolysis. Polyvinyl alcohols of lower degree of hydrolysis than the so-called fully hydrolyzed products, such as the "partially hydrolyzed" grades (80-95% by weight hydrolyzed) are almost completely soluble in water at room temperature, while the fully hydrolyzed products have more limited cold water solubility.
Changes in the degree of polymerization affect solution viscosity; i.e. the viscosity of "fully hydrolyzed" and "partially hydrolyzed" products of low viscosity (in 4% aqueous solution at 20° C.) are about 10 cps, medium viscosity are in the range of about the 20-35 cps, and high viscosity are in the range of about 40 cps and above. The viscosity of the aqueous solution of the polyvinyl alcohol is thus an indication of the degree of polymerization.
Surface sizing of paper with aqueous mixtures of polyvinyl alcohol and boric acid is disclosed in U.S. Pat. No. 3,438,808. The boric acid in admixture in the amount of 15% or more of the polyvinyl alcohol and applied in heated condition to the wet, inhibits the extent of penetration or migration of the sizing composition into the paper.
Vinyl acetate copolymer emulsions containing polyvinyl alcohol as a protective colloid are known in the art for use as adhesives, thickeners, coating compositions and the like. Such compositions comprising vinyl acetate-ethylene copolymer emulsions are disclosed, for example, in U.S. Pat. Nos. 3,355,322; 3,708,388; and 3,906,135.
According to U.S. Pat. No. 3,213,051, quick-setting laminating adhesives are prepared by incorporation of boric acid in a polyvinyl acetate emulsion containing polyvinyl alcohol as a protective colloid. To prevent excessive thickening of the emulsion in storage, a viscosity stabilizer and gelation retarding agent is incorporated therein, such as a thiocyanate or urea.
It is also known to employ certain resins and other polymeric materials as binders or coatings on nonwoven fabrics used as toilet-flushable products such as wrappers or outside coverings for diapers and sanitary napkins, surgical dressings and the like, wherein such fabrics need have during their intended use sufficient tensile strength not to disintegrate while in contact with body fluid discharges. Among binders suggested for use in such fabrics are aqueous dispersions of mixtures of acrylic resins and polyvinyl alcohol, as disclosed, for example, in U.S. Pat. No. 3,561,447. In U.S. Pat. No. 3,480,016 it is proposed to employ as a binder for such nonwoven fabrics used for absorbing body discharge, a polymer resin which is (1) stable in neutral or acidic media but which dissolves or degrades in alkaline media or (2) a polymer resin which is stable or insoluble in neutral or alkaline media but soluble or degradable in acidic media; or (3) polymers degraded by oxidizing agents. To dispose of such fabrics after use, the suitable degrading agent is added to the flush water. Among the examples of alkaline degrading agents disclosed are ammonium borate and alkali metal borates. Among the acidic degrading agents named are boric acid and inorganic acid salts.
The use of cold water soluble polyvinyl alcohol in the absence of other resins or polymers as such bonding agent for disposable nonwoven fabrics, is disclosed in U.S. Pat. Nos. 3,654,928; 3,689,314; 3,692,725; and 3,808,165. To prevent premature structural weakening or disintegration of the fabric as a result of dissolution of the polyvinyl alcohol binder in the presence of body discharge fluids the polyvinyl alcohol film is oversprayed with a gelling or insolubilizing agent such as borax or a mixture reacting to form alkali metal borate in situ. The borax or alkaline borate is stated to react with the polyvinyl alcohol and cross-link at least the exposed surface areas to a sufficient degree to render the reacted binder, when dried, somewhat water resistant. When the treated fabric is exposed to a large excess of water, the borax is said to be leached out and thus enough of the cross-linkages in the polymer are destroyed to reduce water resistance to a non-effective level.
SUMMARY OF THE INVENTION
The foregoing drawbacks of the prior art wet-packaged tissues are overcome by the products of the present invention wherein such wet packaged cloths are made of nonwoven fibers coated or impregnated with a binder comprising a dried emulsion of a vinyl acetate-ethylene copolymer containing polyvinyl alcohol as a protective colloid. The cloths are packaged in contact with an aqueous cleansing liquid containing a compound serving to temporarily insolubilize the binder, such as boric acid, thereby preserving adequate wet strength of the cloth during packaged wet storage and use of the cloth by the consumer yet permitting safe disposition thereof, after such use, by flushing in plain water without danger of clogging conventional plumbing equipment.
Among the objects of the present invention are to provide a pre-moistened towelette or skin cleansing wiper having sufficient wet tensile strength throughout its shelf life and during intended use by the consumer, and which after use may be discarded safely by flushing in plain water without danger of clogging the plumbing system.
To attain such objectives nonwoven fibrous webs are treated with an aqueous emulsion or latex of polyvinyl acetate (PVAc) or vinyl acetate/ethylene copolymers (PVAc/E) containing polyvinyl alcohol as a protective colloid, and the webs dried to form a surface coating. Sheets of such coated web of suitable desired size for use as disposable wet skin cleansing tissues, are folded and packaged while wet in contact with an aqueous solution of boric acid in a concentration up to the limits of its solubility or with an aqueous solution of a soluble salt having an acid to neutral pH on hydrolysis and in a concentration of up to about 20 percent by weight.
DETAILED DESCRIPTION
The initial treatment to coat or impregnate the nonwoven fabric, such as absorbent paper, with the emulsion of PVAc or PVAc/E may be carried out by immersing webs or running lengths of the fabric in the emulsion or by applying the emulsion thereon to the surfaces of the fabric by spraying, by padding or by other type of application. Following drying, the treated web may then be cut to the desired size sheets for the intended use. If desired, of course, individual sheets per-cut to desired size may be treated with the emulsion.
The emulsion used as the impregnant comprises 100 to 40% by weight vinyl acetate and 0 to 60% by weight ethylene. The emulsion is prepared by emulsion polymerization of vinyl acetate alone or with ethylene at pressures substantially greater than atmospheric in the presence of 1 to 10 parts by weight polyvinyl alcohol, preferably 2 to 6 parts by weight, per 100 parts of emulsion as a protective colloid to stabilize the emulsion. The polyvinyl alcohol or mixture of such polyvinyl alcohols is of the cold water soluble or at least cold water dispersible type of being less than 99% hydrolyzed, preferably 80-90% hydrolyzed polyvinyl acetate, and having a low to medium viscosity (4 to 30 cps.). The emulsion containing the protective colloid should contain 50 to 65& by weight total solids and have a viscosity in the range of 1,000-2,000 cps. The amount of emulsion applied to the nonwoven fabric is such as to provide 2 to 50% by weight dry add-on, preferably 5 to 20% by weight.
The nonwoven fabric web may be of any of the types heretofore employed for disposable towelettes or wipes such as those comprising carded or randomly oriented or cross-laid fibers. The fibers may be of natural or regenerated cellulose, other synthetic or proteinaceous fibers of biodegradable materials, or mixtures of these.
The finished towelettes or wipes of desired dimensions may be individually packaged, preferably in folded condition, in moisture proof envelopes or in containers holding any desired number of such folded sheets. For individual packaging it will be convenient to wet the folded sheet with the boric acid solution piror to inserting the same into the envelope, or the liquid may be injected into the open envelope which is thereafter sealed. If a number of the wet sheets are to be packaged in a single container which can be closed and reopened for removal of individual towelettes or wipes as needed, the folded sheets may either be pre-moistened with the boric acid solution or such solution may be poured over the stacked sheets in the container under conditions assuring appropriate wetting of each of the individual sheets therein. Preferably, the concentration of the boric acid solution is at least 1% by weight up to the limits of its solubility in water. More preferably, the boric acid concentration is in the range of about 3 to 5% by weight, with 5% being the solubility limit of boric acid at room temperature.
Various forms of impermeable envelopes for containing wet-packaged materials such as towelettes, wiping and polishing cloths and the like are well-known in the art. Any of these may be employed in packaging the wetted towelettes of the present invention. The envelopes for individual packaging may be formed of any material impervious to the liquid contents and not adversely affected thereby. Thus, the envelopes may be made of plastic materials or of cellulosic materials lined or coated with plastic or other waterproof compositions. Preferably, the envelope should be of a type that can be conveniently opened by tearing to remove the packaged wet towelette.
The following examples are illustrative of various features of articles of this invention and their method of preparation. Unless otherwise indicated in these examples, percent refers to weight percent.
EXAMPLE 1
A 60% vinyl acetate-40% ethylene copolymer emulsion containing 4% PVOH (75% VINOL 205 and 25% VINOL 523) by weight of the copolymer, and containing a total of 52% solids was cast to form a film of 15 mil wet thickness and air dried. While the film retained its definition when immersed in water, it exhibited practically no wet tensile strength as evidenced by the fact that it could not suspend its own weight.
VINOL 205 is a partially hydrolyzed PVOH grade (87-89% hydrolyzed) of low viscosity (4-6 cps) and VINOL 523 is also a partially hydrolyzed PVOH grade (87-89% hydrolyzed) of medium viscosity (about 23 cps).
When immersed in a 5% boric acid solution, the film exhibited surprisingly good wet tensile strength and was highly elastic. However, this film removed from the boric acid solution was redispersed in plain water in less than two minutes.
The treated film in contact with boric acid solution retained wet tensile strength for more than 30 days at 130° F. (54.4° C.) At 160° F. (71.1° C.) the film retained wet tensile strength for 3 days indicating excellent film stability and shelf life at the elevated temperatures that may be experienced under storage conditions.
EXAMPLE 2
The same emulsion as employed in Example 1 was diluted and applied to a paper substrate.
The emulsion was diluted with water to a 25% total solids content and applied to both sides of a 42 pound/3300 square foot (19 kg/307 /square meters) paper substrate, and the treated paper dried at 120° C. in a forced air oven. The pick-up was 3.5 pounds (1.59 kg) dry emulsion.
A sample of the dried emulsion treated paper, as determined by conventional Instron test, showed a wet tensile, after immersion in water, of 1.08 pounds (0.49 kg) as compared to the untreated stock which showed a wet tensile of 0.72 pounds (0.33 kg).
A duplicate sample of the dried emulsion treated paper immersed in 5% boric acid solution for 2 minutes when treated by Instron exhibited a tensile of 1.41 pounds (0.64 kg). When reimmersed in plain water for 2 minutes, the paper returned to about its initial wet strength, 1.09 pounds (0.49 kg).
Another duplicate sample of the dried emulsion treated paper was immersed in 5% boric acid solution for 30 minutes maintained about the same tensile as that previously shown for the boric acid treatment while the water value on reimmersion decreased to 0.91 pounds (0.41 kg).
It should be noted that the paper in the foregoing example had a relatively low dried emulsion add-on. At higher add-on levels or lower basis weight substrate greater relative increase in tensile may be realized.
EXAMPLE 3
While in the foregoing examples, boric acid is employed as the agent for increasing the wet strength of the nonwoven fiber sheet during storage and use, certain water soluble salts known to react with polyvinyl alcohol to effect precipitation or gelling thereof, may be employed. These are less preferred than boric acid, however, since larger concentrations of these are required for the desired purpose.
A list of such soluble salts for gelling or precipitating polyvinyl alcohol is reproduced in the table below. Table 1 shows the minimum concentration causing precipitation of the salts and boric acid dissolved in a 5% solution of polyvinyl alcohol (98-99% hydrolyzed, degree of polymerization 1700-1800).
TABLE 1*______________________________________Minimum Concentrationfor salting outCompounds (g/l)______________________________________(NH.sub.4).sub.2 SO.sub.4 66Na.sub.2 SO.sub.4 50K.sub.2 SO.sub.4 61FeSO.sub.4 105MgSO.sub.4 60Al.sub.2 (SO.sub.4).sub.3 57KAl(SO.sub.4).sub.2 58Potassium citrate 38H.sub.3 BO.sub.3 16.5______________________________________ *Data on the soluble salts of Table 1 were taken from Finch C. A., POLYVINYL ALCOHOL, 1973; John Wiley & Sons, Ltd. Table 23 at page 40.
*Data on the soluble salts of Table 1 were taken from Finch C. A., POLYVINYL ALCOHOL, 1973; John Wiley & Sons, Ltd. Table 23 at page 40.
Table 1 indicates, for example, that sodium sulfate will effect precipitation of a 5% solution of fully hydrolyzed polyvinyl alcohol at a salt concentration of 0.7 normality (50 grams/liter); boric acid will do so at 0.8 normality or 16.5 grams/liter.
EXAMPLE 4
Cast films of the same emulsion as employed in Example 1 (1"×6"=2.5×15.24 cm) were separately tested to determine solubility respectively in boric acid solutions and in sodium sulfate solutions at different concentrations. The results are reported in Table 2.
TABLE 2______________________________________Solute Filmg/100 cc water description______________________________________Sodium sulfate0 Weak film.5 Some film strength development.20 Stronger film.Boric acid0 Weak film.1 Some film strength development.3 Stronger film.5 Optimum film strength.______________________________________
From the foregoing results, it appears that while the soluble salts, such as sodium sulfate, can be employed to retard solubilization of polyvinyl acetate films, somewhat greater concentrations, i.e. about 3 to about 20%, are required than when using boric acid.
As projected from the data set forth in Tables 1 and 2, potassium citrate appears to be even more efficient than sodium sulfate in the articles of this invention.
Specific modes of preparing the packaged towelettes of the present invention have been described above. It is contemplated that other ingredients commonly found in towelettes of the prior art can be included in the package of this invention without departing from its spirit. Such ingredients include a humectant such as propylene glycol, skin protecting agents such as allantoin or resorcinol and a variety of perfumes and other scenting agents. All such variations that fall within the scope of the appended claims are intended to be embraced thereby. | Nonwoven fibrous sheets impregnated with latices of polyvinyl acetate or its copolymers containing polyvinyl alcohol, intended for use in pre-moistened condition as skin cleansing tissues, are folded and packaged in closed containers or in individual sealed water impervious envelopes; said packaged sheets being maintained in contact with a dilute aqueous solution of a precipitating or gelling agent for polyvinyl alcohol, such as boric acid. The agent imparts improved wet tensile strength to the sheet during storage and use by the consumer but permits the sheet to be safely disposed of, after use, by flushing in plain water without danger of clogging the plumbing system. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Italian Application No. MI2013A000768 filed on May 10, 2013, which is incorporated herein by reference in its entirety.
FIELD
[0002] The present invention refers to a showcase for preserving and displaying objects in a protected environment, typically such as artworks, cultural heritage objects or however delicate objects, in museums, exhibitions and the like.
BACKGROUND
[0003] The expression “protected environment” herein and hereinafter refers to an environment in which the atmosphere is controlled, through the monitoring of one or more parameters among temperature, relative humidity, dust content, pollutant content, with the aim of maintaining the conditions provided for preserving the displayed objects, and in which access thereto by unauthorised personnel is prohibited, so as to avoid theft or damage of the displayed objects.
[0004] Thus, showcases of this type must meet various types of requirements, in view of the preservation and entirety of the displayed objects. In addition, obviously, these showcases are required to guarantee the best visibility for the displayed objects so as to allow operators managing museums and exhibitions to organise suitable exhibition paths, depending on the cultural message intended to be transmitted.
[0005] Especially when the objects to be displayed are extremely sensitive, the climatic conditions must be controlled in a very painstaking and accurate manner, so as to avoid damaging the objects. In addition, obviously different objects often require different climatic conditions. Hence, it often occurs that the arrangement of objects in the same museum space is conditioned by requirements related to the correct preservation of the single objects to be displayed and the exhibition needs, which should lead to distributing the objects according to cultural criteria of sequence and matching between various objects. On the contrary, the preservation needs sometimes lead to grouping in the same showcases objects with the same climatic need, even when the logical arrangement for a better access for the public would be different, or to often use showcases for single objects, thus determining an increase of the number of showcases that determines not only high costs but also a fragmentation of the display which may jeopardize the cultural message.
[0006] Those managing sensitive museums and exhibition objects, which require predetermined climatic conditions, thus feel the need of having innovative instruments capable of allowing them greater freedom of display of such objects in the display paths, though in the most scrupulous respect of the ideal preservation climatic conditions
SUMMARY
[0007] Thus, the present invention regards a showcase according to claim 1 . Preferred characteristics are indicated in the dependent claims.
[0008] More in detail, the invention regards a showcase for preserving and displaying objects in a protected environment, comprising a display space and adjustment and control means for maintaining predetermined climatic conditions of the air in the display space, wherein the adjustment and control means comprise an air treatment path outside the display space as well as openings for delivering conditioned air from the treatment path to the display space and openings for returning the conditioned air from the display space to the treatment path, characterised in that it comprises in the same display space at least two display areas having predetermined different climatic conditions from each other, not separated by any wall, wherein, for each display area:
the delivery openings and return openings comprise area-specific delivery and return openings, and the area-specific delivery openings of each of the display areas receive—from the treatment path—area-specific conditioned air having climatic conditions suitable for maintaining the predetermined specific climatic conditions for such display area.
[0011] The presence of display areas with different climatic conditions allows arranging in this showcase several objects, also with preservation needs different from each other; thus, the display paths may be defined with greater freedom, without requiring an excessive number of showcases.
[0012] The different climatic conditions from each other in the different display areas may include different conditions relative humidity and/or different temperature conditions. Vice versa, generally it will not be necessary to provide for different cleaning conditions against dust or pollutant agents, in that objects less sensitive than these factors are definitely not damaged if preserved in cleaner spaces than strictly necessary.
[0013] In a preferred embodiment, in each display area:
[0014] the area-specific delivery openings are distributed on a first wall of the showcase facing the display area and
[0015] the area-specific return openings are distributed on a second wall of the showcase facing the display area and opposite to the first wall.
[0016] The arrangement on the opposite walls of the area-specific delivery and return openings facilitates the correct distribution of the airflow inside each display area.
[0017] Preferably, in each display area the area-specific delivery openings and the area-specific return openings are distributed uniformly on the first and respectively on the second wall.
[0018] This particularly allows to obtain in each display area a laminar flow of the conditioned air. Laminar flows (contrary to the turbulent flows) are unidirectional flows made up of extremely regular fluid streams that flow parallel from each other and do not mix. The laminar flows of conditioned air in each display area, between the respective area-specific delivery and return openings, wind each object present in the area and thus prevent the air in the different areas from mixing, though in the absence of walls or barriers (even air barriers).
[0019] In order to facilitate the obtainment of the aforementioned laminar flows, it is suitable that the emission of conditioned air from the area-specific delivery ports be suitably controlled. Preferably, in each display area, the area-specific conditioned air exits from all area-specific delivery openings at the same speed, and even more preferably the speed of the area-specific conditioned air at the area-specific delivery openings is of 0.30-0.50 m/s. Thus, this allows to easily obtain the desired laminar flow.
[0020] In a preferred embodiment, in each display area, the area-specific conditioned air exits from the area-specific delivery openings at a speed proportionally as high as vicinity to other display areas. The higher speed of the air in the so-called border areas between different display areas adjacent with respect to each other allows to create a given barrier effect; such barrier effect is such to increase the already ideal separation from among obtained areas due to laminar flows.
[0021] Preferably, the speed of the area-specific conditioned air is in this case of 0.05-0.65 m/s at the area-specific delivery openings. These values revealed to be efficient at obtaining both the desired barrier effect between different display areas and the desired laminar flow inside the single display areas.
[0022] In a preferred embodiment, in each display area, the area-specific delivery openings and the area-specific return openings are distributed on the first and respectively on the second wall in proximity of one or more adjacent display areas.
[0023] This arrangement allows an air barrier which allows to separate the areas from each other, so that they can be maintained in different climatic conditions. The conditioned air introduced into each area does not mix with the conditioned air introduced in other areas, thus guaranteeing to maintain different climatic conditions; actually, there is no convective exchange between different areas and the constant exchange of the conditioned air makes the effect of the possible heat exchange by conduction or radiation marginal.
[0024] Preferably, in each display area, the area-specific conditioned air exits from all the area-specific delivery openings at the same speed, and even more preferably, the speed of the area-specific conditioned air at the area-specific delivery openings is of 1.50-3.00 m/s. Thus, this allows to easily obtain the desired air barrier effect. Generally, it is suitable that the speed is proportionally high to the height of the showcase.
[0025] Preferably, in each display area, the area-specific return openings are distributed on an area larger than that on which the area-specific delivery openings are distributed. Thus, especially for high showcases, it is easier to recover from the area-specific return openings the air which should be sent to the treatment path, taking into account the general tendency of the delivery air jet to widen towards the inside of the display area.
[0026] The number of display areas may be any, for example also equal to or greater than three. Generally, the higher the number of the areas, the greater the versatility of the showcase.
[0027] Preferably, the treatment path comprises, for each display area, an area-specific delivery plenum upstream of the area-specific delivery openings and/or an area-specific return plenum downstream of the area-specific return openings. Thus, the expression plenum is herein and hereinafter used to describe a portion in the air passage circuit having a much larger section with respect to the other portions of the circuit, so that—therein—the speed—of the air is substantially zeroed. The presence of a plenum immediately upstream and downstream of the display area facilitates the establishment of the laminar flow conditions.
BRIEF DESCRIPTION OF DRAWINGS
[0028] Further characteristics and advantages of a showcase according to the invention shall be more apparent from the following description of preferred embodiments, provided with reference to the attached drawings. In such drawings:
[0029] FIG. 1 is a perspective view of a showcase according to a first embodiment of the invention;
[0030] FIG. 2 is a functional scheme of the showcase of FIG. 1 ;
[0031] FIG. 3 is a perspective view of a showcase according to a second embodiment of the invention;
[0032] FIG. 4 is a functional diagram of the showcase of FIG. 3 ;
[0033] FIG. 5 is a perspective view of a showcase according to a third embodiment of the invention;
[0034] FIG. 6 is a functional scheme of the showcase of FIG. 5 .
DESCRIPTION
[0035] In FIGS. 1 and 2 , a showcase according to a first embodiment of the invention with is indicated in its entirety with 10 . The showcase 10 comprises a base 20 , a box 21 above the base 20 , a roof 24 above the box 21 , and a backrest 25 arranged on the back of the box 21 and adjacent both to the base 20 and to the roof 24 . The box 21 is made up of panels including at least one openable, coupled from each other in a sealing fashion in a per se conventional manner; in the figures, neither the openable panels nor the sealing means are shown, in that not part of the invention.
[0036] The showcase 10 comprises a display space 30 inside the box 21 and adjustment and control means for maintaining predetermined climatic conditions of the air in the display space. These adjustment and control means comprise an air treatment path 40 , housed in the base 20 , in the backrest 25 and in the roof 24 , thus outside the display space 30 , as well as delivery openings 41 of conditioned air from the treatment path 40 to the display space 30 and return openings 42 of the conditioned air from the display space 30 to the treatment path 40 .
[0037] The treatment path 40 comprises equipment and devices (per se known) for measuring and modifying the climatic conditions of the air; for example, they may be provided with heaters, coolers, humidifiers, dehumidifiers, filters of various types, all per se known in the art and thus neither described nor illustrated in detail.
[0038] In the same display space 30 at least two display areas having predetermined different climatic conditions from each other are provided; in particular, in the example of the illustrated showcase 10 , two display areas 30 a and 30 b are provided. The two areas 30 a and 30 b are not separated from each other by any wall, channel or the like; thus, they are solely differentiated by the different climatic conditions therein. These different climatic conditions from each other in the different display areas 30 a and 30 b comprise different relative humidity and/or different temperature conditions.
[0039] The delivery and return openings comprise area-specific delivery 41 a , 41 b and return 42 a , 42 b openings of the conditioned air. The area-specific delivery openings 41 a , 41 b receive from the treatment path 40 area-specific conditioned air having the predetermined specific climatic conditions for the display area 30 a or 30 b . For such purpose, also the treatment path 40 is evidently doubled into two treatment paths 40 a , 40 b , each specific for the respective display area 30 a , 30 b.
[0040] The area-specific delivery openings 41 a , 41 b are distributed uniformly on a first wall 51 a , 51 b of the showcase 10 facing the display area 30 a , 30 b and the area-specific return openings 42 a , 42 b are distributed uniformly on a second wall 52 a , 52 b of the showcase 10 facing the display area 30 a , 30 b and opposite to the first wall 51 a , 51 b.
[0041] In each display area 30 a , 30 b , between the area-specific delivery openings 41 a , 41 b and the area-specific return openings 42 a , 42 b a laminar flow of area-specific conditioned air is established, which traverses the entire display area, as schematically represented by the vectors in FIG. 2 . The area-specific conditioned air exits from all the area-specific delivery openings 41 a , 41 b at the same speed, preferably comprised between 0.30 m/s and 0.50 m/s.
[0042] The conditioned air laminar flows in each display area 30 a , 30 b , between the respective area-specific delivery 41 a , 41 b and return 42 a openings, 42 b , wind each object present in the area 30 a , 30 b and thus prevent the air in the different zones from mixing, though in the absence of walls or barriers of any kind.
[0043] The area-specific delivery 41 a , 41 b and return 42 a , 42 b openings may be formed,
[0044] for example, by a plurality of equal holes.
[0045] The air treatment path 40 may then comprise, for each display area 30 a , 30 b , an area-specific delivery plenum 55 a , 55 b upstream of the area-specific delivery openings 41 a , 41 b and/or an area-specific return plenum 56 a , 56 b , downstream of the area-specific return openings 42 a , 42 b . The presence of the area-specific plenum allows to make the conditioned air flow much more regular, thus facilitating the establishment of laminar motion conditions in the display areas 30 a and 30 b.
[0046] FIGS. 3 and 4 show a showcase 110 according to a second embodiment of the invention. The showcase 110 , analogously to the showcase 10 , comprises a base 120 , a box 121 above the base 120 , a roof 124 above the box 121 , and a backrest 125 arranged at the back of the box 121 and adjacent to both the base 120 and the roof 124 . The box 121 is made up of panels including at least one openable, coupled to each other in a sealing fashion in a per se conventional manner; in the figure, neither the openable panels nor the sealing means are shown, in that not part of the invention.
[0047] The showcase 110 comprises a display space 130 inside the box 121 and adjustment and control means for maintaining predetermined climatic conditions of the air in the display space. These adjustment and control means comprise a treatment path 140 of the air, housed in the base 120 , in the backrest 125 and in the roof 124 , thus outside the display space 130 , as well as delivery openings 141 of conditioned air from the treatment path 140 to the display space 130 and return openings 142 of the conditioned air from the display space 130 to the treatment path 140 .
[0048] The treatment path 140 comprises equipment and devices (per se known) for measuring and modifying the climatic conditions of the air; for example, they may be provided with heaters, coolers, humidifiers, dehumidifiers, filters of various types, all per se known in the art and thus neither described nor illustrated in detail.
[0049] In the same display space 130 at least two display areas having predetermined different climatic conditions from each other are provided; in particular, in the example of the illustrated showcase 110 , two display areas 130 a and 130 b are provided. The two areas 130 a and 130 b are not separated from each other by any wall, channel or the like; thus they are solely differentiated by the presence of different climatic therein. These climatic conditions different from each other in the different display areas 130 a and 130 b comprise different relative humidity and/or different temperature conditions.
[0050] The delivery and return openings comprise area-specific delivery 141 a , 141 b and return 142 a , 142 b openings of the conditioned air. The area-specific delivery openings 141 a , 141 b receive from the treatment path 140 area-specific conditioned air having the predetermined specific climatic conditions for the display area 130 a or 130 b . For such purpose, also the treatment path 140 is evidently doubled into two treatment paths 140 a , 140 b , each specific for the respective display area 130 a , 130 b.
[0051] The area-specific delivery openings 141 a , 141 b are distributed uniformly on a first wall 151 a , 151 b of the showcase 110 facing the display area 130 a , 130 b and the area-specific return openings 142 a , 142 b are distributed uniformly on a second wall 152 a , 152 b of the showcase 110 facing the display area 130 a , 130 b and opposite to the first wall 151 a, 15 lb.
[0052] In every display area 130 a , 130 b , between the area-specific delivery openings 141 a , 141 b and the area-specific return openings 142 a , 142 b a laminar flow of the area-specific conditioned air is established, which traverses the entire display area.
[0053] Contrary to the showcase 10 , the area-specific conditioned air exits from the area-specific delivery openings 141 a , 141 b with different speed. More precisely, the area-specific conditioned air exits with greater speed in area-specific openings proximal to other display areas, more precisely with speed proportionally as high as is greater is the vicinity to other display areas, as schematically represented by the vectors in FIG. 4 . The air speed at the exit of the openings 141 a , 141 b is thus preferably comprised between 0.05 m/s and 0.65 m/s.
[0054] Like in the showcase 10 , the conditioned air laminar flows in each display area 130 a , 130 b , between the respective area-specific delivery 141 a , 141 b and return 142 a , 142 b openings, wind every object present in the area 130 a , 130 b and thus prevent the air in the different areas from mixing, though in presence of walls or barriers of any type.
[0055] In addition, the higher speed of air in the so-called border areas between the different display areas 130 a , 130 b adjacent from each other allows to create a certain barrier effect; this barrier effect is such to increase the already optimal separation from among the obtained area due to the laminar flows.
[0056] Like in the showcase 10 , the area-specific delivery 141 a , 141 b and return 142 a , 142 b openings may for example be formed by a plurality of equal holes.
[0057] The air treatment path 140 may comprise, for each display area 130 a , 130 b , an area-specific delivery plenum 155 a , 155 b upstream of the area-specific delivery openings 141 a , 141 b and/or an area-specific return plenum 156 a , 156 b , downstream of the area-specific return openings 142 a , 142 b . The presence of the area-specific plenums allows to make the conditioned air flow more regular, thus facilitating the establishment of laminar motion conditions in the display areas 130 a and 130 b.
[0058] FIGS. 5 and 6 shows a showcase 210 according to a third embodiment of the invention. The showcase 210 , analogously to showcases 10 and 110 , comprises a base 220 , a box 221 above the base 220 , a roof 224 above the box 221 , and a backrest 225 arranged against the back of the box 221 and adjacent both to the base 220 and to the roof 224 . The box 221 is made up of panels between which at least one is openable, coupled to each other in a sealing fashion in a per se conventional manner; in the figures, neither the openable panels nor the sealing means are outlined, given that they are not part of the invention.
[0059] The showcase 210 comprises a display space 230 inside the box 221 and adjustment and control means for maintaining predetermined climatic conditions of the air in the display space. These adjustment and control means comprise a treatment path 240 of the air, housed in the base 220 , in the backrest 225 and in the roof 224 , thus outside the display space 230 , as well as openings 241 for delivering conditioned air from the treatment path 240 to the display space 230 and openings 242 for returning the conditioned air from the display space 230 to the treatment path 240 .
[0060] The treatment path 240 comprises equipment and devices (per se known) for measuring and modifying the climatic conditions of the air; for example heaters, coolers, humidifiers, dehumidifiers, filters of various kind may be provided, all per se known in the art and thus neither described nor illustrated in detail.
[0061] In the same display space 230 at least two display areas having predetermined different climatic conditions from each other are provided; in particular, in the example of the illustrated showcase 210 , two display areas 230 a and 230 b are provided. The two areas 230 a and 230 b are not separated from each other by any wall, channel or the like; thus, they are solely differentiated by the different climatic conditions to therein. These different climatic conditions from each other in the different display areas 230 a and 230 b comprise different relative humidity and/or temperature conditions.
[0062] The delivery and openings comprise area-specific delivery 241 a , 241 b and return 242 a , 242 b openings of the conditioned air. The area-specific delivery openings 241 a , 241 b receive from the treatment path 240 area-specific conditioned air having the predetermined specific climatic conditions for the display area 230 a or 230 b . For such purpose, also the treatment path 240 is evidently doubled into two treatment paths 240 a , 240 b , each specific for the respective display area 230 a , 230 b.
[0063] The area-specific delivery openings 241 a are distributed on a first wall 251 a of the showcase 210 facing the display area 230 a and in proximity of the display area 230 b ; the area-specific return openings 242 a are distributed on a second wall 252 a of the showcase 210 facing the display area 230 a and in proximity of the display area 230 b ; the second wall 252 a is opposite to the first wall 251 a . The area-specific delivery openings 241 b are distributed on a first wall 251 b of the showcase 210 facing the display area 230 b and in proximity of the display area 230 a ; the area-specific return openings 242 b are distributed on a second wall 252 b of the showcase 210 facing the display area 230 b and in proximity of the display area 230 a ; the second wall 252 b is opposite to the first wall 251 b.
[0064] In every display area 230 a , 230 b , between the area-specific delivery openings 241 a , 241 b and the area-specific return openings 242 a , 242 b an area-specific conditioned air flow, which traverses the entire display area, is established.
[0065] Contrary to showcase 10 and showcase 110 , the area-specific conditioned air which exits from the area-specific delivery openings 241 a , 241 b does not have the laminar flow characteristics, but it is concentrated on the border between the adjacent display areas 230 a and 230 b , forming an air barrier therebetween, as schematically represented by the vectors in FIG. 6 . The speed of the air at the exit from the openings 241 a , 241 b is thus preferably comprised between 1.5 m/s and 3.0 m/s.
[0066] The conditioned air in each display area 230 a , 230 b not only traverses the space directly comprised between the respective area-specific delivery 241 a , 241 b and return 242 a , 242 b openings, but it is extended over the entire display area 230 a , 230 b , thus winding every object present therein. The air barrier formed in proximity of the border between the two display areas 230 a and 230 b prevents the air in the different areas from mixing, though in the absence of walls or barriers of any kind.
[0067] Preferably, in each display area 230 a , 230 b , the area-specific return openings 242 a , 242 b are distributed on an area larger than that on which the area-specific delivery openings are distributed 241 a , 241 b . Thus, especially if the showcase 210 is relatively high, is easier to recover from the area-specific return openings 242 a , 242 b the air to be conveyed to the treatment path 240 , considering the natural tendency of the delivery air jet to expand towards the inside of the display area 230 a , 230 b.
[0068] Like in showcase 10 and showcase 110 , the area-specific delivery 141 a , 141 b and return 142 a , 142 b openings may for example be formed by a plurality of equal holes.
[0069] The air treatment path 240 may comprise, for each display area 230 a , 230 b , an area-specific delivery plenum 255 a , 255 b upstream of the area-specific delivery openings 241 a , 241 b and/or an area-specific return plenum 256 a , 256 b , downstream of the area-specific return openings 242 a , 242 b . The presence of the area-specific plenums allows to make the conditioned air flow much more regular, thus, in this case, facilitating the maintenance of a separation between the two adjacent conditioned air flows which form the air barrier between the display areas 230 a and 230 b.
[0070] The illustrated showcases 10 , 110 , 210 have two display distinct areas; it is obviously possible that the showcases according to the invention have three or more distinct display areas, variously arranged in the showcase. | This showcase for preserving and displaying objects in a protected environment comprises a display space and adjustment and control means for maintaining predetermined climatic conditions of the air in the display space. The adjustment and control means comprise an air treatment path outside the display space as well as openings for delivering conditioned air from the treatment path to the display space and openings for returning the conditioned air from the display space to the treatment path. The showcase comprises in the same display space at least two display areas having predetermined different climatic conditions from each other, not separated by any wall. The presence of display areas with different climatic conditions allows to arrange—in this showcase—several objects, even with the aim of different preservation needs with respect to each other. | 5 |
RELATED APPLICATION
[0001] This application is a continuation-in-part of application Ser. No. 10/956,189, entitled “Air Ionization Module and Method,” filed on Sep. 30, 2004, which application is incorporated herein in the entirety by this reference thereto.
FIELD OF THE INVENTION
[0002] This invention relates to an ionizing system and more particularly to a self cleaning electrode system that includes a filamentary ion emitting electrode.
BACKGROUND OF THE INVENTION
[0003] Air ionizers that use gas, such an air, to disperse ions typically operate by moving the gas past ionizing electrodes that produce ions due to corona discharge in response to high ionizing voltage applied to the electrodes.
[0004] The moving gas disperses ions in a flowing stream toward objects to be charged or discharged. Particles, usually present in air, accumulate on a highly-charged surface of ionizing electrodes, thus reducing ion output and changing a balance between generated positive and negative ions produced by the ionizing electrodes.
[0005] Conventional methods and apparatuses for cleaning pointed or needle-like ionizing electrodes commonly include manually operated brushes that sweep tips of ionizing electrodes and dislodge accumulated particles. Alternatively, brushes installed on a rotating hub of a fan that produces the flow of gas relies upon centrifugal force to move the brushes in and out of contact with ionizing electrodes to dislodge accumulated particles.
[0006] In ionizers having an ionizing electrode formed as a thin wire (filament), the ionizing electrode also attracts particles and requires periodic cleaning. Such filament can also be cleaned manually as by brushing but over a substantially larger area than for ionizers with emitter points. And, areas next to supports for a filament cannot be sufficiently cleaned by a rotating brush.
SUMMARY OF THE INVENTION
[0007] In accordance with one embodiment of this invention, a filament stretched to a polygonal shape is cleaned by sliding the filament against supports that support the flexible filament in the polygonal shape.
[0008] An air ionizer includes an ionizing filament stretched between supports into a polygonal shape that is disposed within a flowing air stream. The filament slides against the supports to dislodge accumulated particles. In accordance to one embodiment of the present invention both ends of the filament electrode are attached to a lever that provides connection between the filament and a high voltage power supply. Sliding movement of the filament is produced by moving the lever or by moving the filament supports, or both. In another embodiment of the present invention high ionizing voltage can be supplied through at least one filament support and the lever can be fully situated within an area of a flowing air stream.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a frontal view of an ionizing blower from the impeller side of the fan module in accordance with one embodiment of the present invention.
[0010] FIG. 2A and FIG. 2B are frontal views of an ionizing blower from the impeller side of the fan module showing a lever mechanism in accordance with another embodiment of the present invention.
[0011] FIG. 3 is a frontal partial view of an ionizing blower from the impeller side of the fan module showing a lever mechanism in accordance with yet another embodiment of the present invention.
[0012] FIG. 4 is a frontal view of an ionizing blower from the side opposite the impeller side of the fan module showing another lever mechanism in accordance with yet another embodiment of the present invention.
[0013] FIG. 5 is a detailed isometric view of a filament support and cleaning module in accordance with yet another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] In one embodiment of the present invention, as illustrated in FIG. 1 , rotary fan module 1 operates to move the air in an airflow direction. An ionizing electrode in a form of a filament (corona wire) 20 is stretched in a polygonal shape between wire supports 11 that are attached to cylindrical support structure 10 to position the filament in an area of maximum airflow and close to the outer edges of fan blades 2 .
[0015] Of course, the filament 20 can be situated on the inlet side of the fan module 1 where hub 3 is situated, for example, on the opposite or output side of the fan. Wire supports 11 may be shaped as hooks, eyelets, cylinders, or other suitable shape for supporting the filament 20 in stretched configuration, as shown, and facilitating the sliding of the filament 20 through the supports 11 .
[0016] Both ends of the filament 20 are attached to lever 30 at separate attachment points 31 and 32 , or optionally at the same point. Lever 30 extends outside of the support structure 10 and is situated between adjacent wire supports 13 and 14 within a cut-out area 12 of the support structure 10 .
[0017] High ionizing voltage is connected to corona wire 20 via a conductor 37 along lever 30 , as shown. Alternatively, high ionizing voltage may be supplied to the filament 20 through a wire support 11 , or via other convenient connection.
[0018] Lever 30 is mounted for movement along a cleaning path 40 that is substantially parallel to segment 21 of the polygon shape of filament 20 , with the attachment points 31 and 32 remaining located along segment 21 . The filament 20 thus slides along or through supports 11 to dislodge accumulated particles. Segment 21 may be longer than other segments of polygonal shape of filament 20 to facilitate cleaning of a full length of the filament 20 , including areas adjacent to the supports 11 , in response to movement of the lever 30 along the cleaning path 40 .
[0019] Lever 30 can be moved along the cleaning path manually, or by solenoid, pneumatic cylinder, or other suitable known device and the lever 30 can occupy any position within area 12 of the support structure 10 after a cleaning procedure, or can be moved back to an original position.
[0020] In another embodiment of present invention, as shown on FIG. 2A , the support structure 10 of the fan module 1 is rotatable substantially coaxially with the rotary fan and hub 3 to facilitate cleaning of the filament 20 by rotating the support structure 10 along cleaning path 42 while retaining the filament 20 in fixed position. The axis of rotation of the support structure 10 is substantially coincident with the center of the polygon formed by filament 20 .
[0021] FIG. 2 b shows a partial view of the same area of the fan module 1 as shown in FIG. 2 a and illustrates compensation for changes in length of the perimeter of the polygon formed by filament 20 . During a cleaning procedure the lever 33 and the attachment points 34 and 35 for the filament 20 that are carried by the lever 33 are shown moving along the arc in this illustrated embodiment, and such attachment points deviate from the line intercept 23 between supports 13 and 14 . Because the sum of the lengths of segments 21 and 22 of the filament 20 is greater than the length of the line intercept 23 , there is a need to compensate for the changes in required length of the filament 20 during movement of the lever 33 over the cleaning path 41 . This is achieved by attaching filament 20 to spring 36 , or other elastic element, or by otherwise accommodating changing distance between attachment points 34 and 35 . One such technique includes resilient supports 13 , 14 , or other supports 11 , that can adjust at least radially to accommodate a fixed length of filament 20 so moved along the cleaning path 41 .
[0022] In another embodiment of the present invention, as shown on FIG. 3 , the filament 20 is moved along a cleaning path via pivoted lever 50 . FIG. 3 shows a partial view of the same region of the fan module 1 as FIGS. 2 a and 2 b . Lever 50 is disposed to rotate around pivoting point 55 along path 43 within the region 12 between supports 13 and 14 . Pivoting point 55 may be situated outside of the support structure 10 , or optionally within the perimeter of the support structure 10 . Elastic element such as spring 53 may be mounted on lever 50 to accommodate changes in the required length of filament 20 as lever 50 is moved along the cleaning path 43 .
[0023] In another embodiment of present invention the filament 20 is disposed on the output side of the fan module 1 where the support 5 for the fan motor is located. FIG. 4 shows the support structure 10 installed coaxially with the rotational axis of the fan blades 2 on the output side of the fan module 1 . Lever 70 is mounted on the support 5 for pivotal movement around pivoting point 72 that may be positioned concentrically with the polygon formed by filament 20 . Lever 70 rotates along path 48 between supports 13 and 14 , and compensation for the required changes in filament length is achieved by altering the distance 77 between filament attachment points 75 and 76 . In one embodiment of the present invention, the attachment point 76 is located on lever 70 and attachment point 75 is located on an auxiliary lever 71 that pivots around pivoting point 73 located on lever 70 . Elastic element such as spring 74 between levers 70 and 71 maintains tension on filament 20 and compensates for change in required length of filament 20 during movement of lever 70 along the cleaning path 48 . Of course, a single U-shaped lever made of elastic material may serve the same purpose. High ionizing voltage is supplied to filament 20 through support 15 . Cleaning of the filament 20 is accomplished by rotating the support structure 10 while holding the filament 20 in fixed position, while sliding the supports 11 , 13 , 14 , 15 over the filament, or by rotating lever 70 to slide the filament 20 through the supports 11 , 13 , 14 , 15 in fixed position.
[0024] One or more of the supports 11 can protrude radially outside of the support structure 10 to facilitate both ease of rotating and, additionally, can intrude radially and be shaped as vanes for redirecting (collimating) the ionized air stream formed by the apparatus as described. Of course, the pivoting point 72 on lever 70 can also be placed outside the perimeter of support structure 10 .
[0025] Movement of support structure 10 , or of lever 70 , can be performed manually, or via an actuator such as solenoid 90 mounted on support 5 to apply force 49 to rotate the lever 70 .
[0026] Referring now to FIG. 5 , there is shown a detailed view of the support structure and cleaning mechanism according to another embodiment of the present invention. The support structure comprises a body that includes a lower ring 16 and an upper ring 17 . Each ring includes lower and upper portions of the supports 161 and 171 , respectively. These supports form non-circular apertures 180 in which split bushings 18 can be placed and secured by protrusions 181 . Rings 16 and 17 can be molded of inexpensive plastic and the bushings 18 can be formed of material such as ceramic with high hardness and good resistivity to plasma and vibration. Bushings 18 are keyed by non-circular apertures 180 in a particular way with a radial split 182 oriented outwardly from the center of the support structure. Stretched filament 20 only contacts inner surfaces of the bushings 18 , and does not contact plastic rings 16 and 17 . The distance between supports 162 and 172 and 163 and 173 may be larger than between other supports. Lever 190 is pivotally mounted to rotate around shaft 191 , substantially concentrically within the support structure, along path 198 . Arms 192 and 193 of the lever 190 serve as flat resilient springs between supports 162 / 172 and 163 / 173 . The ends of filament 20 are attached at points 194 and 195 on respective arms 192 and 193 of the lever 190 . Spring resilience of the arms 192 and 193 keeps the filament 20 in tension and helps compensate for required length changes of the filament during a cleaning procedure in which the filament 20 is pulled through bushings 18 to remove adherent contaminants. The support structure may be rotated relative to the filament 20 retained in fixed position, or the lever 190 and filament 20 may be rotated relative to the bushings 18 held in fixed position.
[0027] High ionizing voltage is supplied to the filament 20 via pin 200 that protrudes outside the support structure for connection to a high ionizing voltage supply. Pin 200 may include a slot 201 for engaging the filament 20 and can protrude through hole 202 in support structure. Alternatively, high ionizing voltage may be supplied to filament 20 via at least one conductive bushing 18 that connects to a supply of high ionizing voltage. Also, high ionizing voltage can be supplied to filament 20 through contactless capacitive connection.
[0028] The shaft 191 is mounted on plate 196 that is supported via ribs 197 that may be formed as an integral portion of ring 16 . The lever 190 with a predetermined length of filament 20 attached thereto can be mounted on shaft 191 with the filament 20 placed into the partial holes 180 in the lower ring supports. The upper ring 17 is then attached to lower ring 16 with glue, snaps, or other known attachment schemes. Then, bushings 18 with radial splits 182 are slipped over the filament 20 and snapped into holes 180 to configure and tension the filament 20 in a polygonal shape. This forms the entire assembly for attachment outside of a fan module and for easy removal to reduce cost of construction, maintenance and repair. | A module for generating ions in a flowing air stream includes a support structure having a central region adapted to pass a flowing air stream therethrough, and including a plurality of supports for positioning a filamentary ion-generating electrode in a polygonal configuration within the central region. The supports and filament are relatively moveable to wipe the surface of the filament at each support for removing accumulated contaminants on the filament. | 7 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This non-provisional patent application is a continuation-in-part of U.S. application Ser. No. 13/776,925, filed on Feb. 26, 2013, which is a continuation-in-part of U.S. application Ser. No. 12/942,243. The original application was filed on Nov. 9, 2010. It is listed the same inventor.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
MICROFICHE APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of beverage holders. More specifically, the present invention comprises a modular beverage holder that includes at least a height adjusting feature and preferably an angular rotation adjusting feature as well.
2. Description of the Related Art
The need to provide a resting surface for beverage containers has long been recognized. The simplest solution to this problem is the provision of an end table (for a couch or chair) or a nightstand (for a bed). These pieces of furniture provide a horizontal surface near the user's position. The user may then place his or her beverage on this horizontal surface.
Of course, end tables and nightstands are relatively expensive and fixed in one location. Thus, some inventors have explored the possibility of a less expensive solution which may be attached directly to the furniture itself. An example of this approach is found in U.S. Pat. No. 4,836,113 to Waddell (1989). The Waddell device provides a flat tray adjacent to a bed frame. A similar approach is taken in U.S. Pat. No. D550,981 to Watson (2007) and U.S. Pat. No. 5,038,434 to Navarrette (1991).
A particular problem recognized in the prior art is the provision of a beverage holder for a hospital bed. It is generally not practical to provide a stationary end table or nightstand next to a hospital bed, since access must be provided to all portions of the patient. In addition, side rails and other features of the bed are designed to slide or fold away rapidly. Any beverage holder is preferably compatible with the existing hardware and preferably easy to remove in the event that rapid access to the patient is requires. The present invention solves these and other problems, as will be described more particularly in the following text.
BRIEF SUMMARY OF THE INVENTION
The present invention comprises a beverage container holder adapted to hold a wide variety of containers including cups, bottles, mugs, and tumblers. The device preferably includes a base, an upright extending upward from the base, and a receiver near the top of the upright. The receiver preferably includes a cup holder which is preferably made detachable so that it may be washed in a dishwasher. In a preferred embodiment of the present invention, the receiver includes at least one pocket having dimensions capable of accommodating a cellular phone, remote control, or other device.
The height of the receiver with respect to the base is adjustable in the present invention. The rotation of the receiver with respect to the base is preferably also made adjustable. The adjustment mechanism may preferably be activated using only one hand.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a perspective view, showing a preferred embodiment of the present invention.
FIG. 2 is a perspective view, showing the embodiment of FIG. 1 attached to a bed.
FIG. 3 is a perspective view of an alternate embodiment, including a larger base.
FIG. 4 is a detailed perspective view, showing the detachable cup holder in its receiver.
FIG. 5 is an exploded perspective view, showing the cup holder removed from the receiver.
FIG. 6 is a detailed perspective view, showing a coffee cup retained by the cup holder.
FIG. 7 is a detailed perspective view, showing a can retained by the cup holder.
FIG. 8 is a detailed perspective view, showing a tumbler retained by the cup holder.
FIG. 9 is a detailed perspective view, showing an alternate embodiment of the cup holder and receiver.
FIG. 10 is a perspective view, showing still another embodiment of the present invention.
FIG. 11 is a perspective view, showing the height-adjusting feature of the embodiment of FIG. 10 .
FIG. 12 is a perspective view, showing the rotation-adjusting feature of the embodiment of FIG. 10 .
FIG. 13 is an exploded perspective view, showing the components of the locking mechanism used in the embodiment of FIG. 10 .
FIG. 14 is an exploded perspective view, showing the components of FIG. 13 in greater detail.
FIG. 15 is a sectional view, showing the locking mechanism components of FIG. 13 in a locked state.
FIG. 16 is a sectional view, showing the locking mechanism components of FIG. 13 in an unlocked state.
FIG. 17 is a perspective view, showing still another embodiment of the present invention.
FIG. 18 is a detailed perspective view, showing the receiver and cup holder of the embodiment of FIG. 17 .
FIG. 19 is a perspective view, showing the height-adjusting feature of the embodiment of FIG. 17 .
FIG. 20 is an exploded perspective view, showing the components used in the locking mechanism of the embodiment of FIG. 17 .
FIG. 21 is a perspective view, showing the rotation-adjusting feature of the embodiment of FIG. 17 .
FIG. 22 is a perspective view, showing an alternate embodiment of the present invention.
FIG. 23 is a perspective view, showing the cord securing feature of the embodiment of FIG. 22 .
FIG. 23A is a detail view, showing more detail of the cord securing slot located in the receptacle.
FIG. 24 is a perspective view, showing an electronic device charger placed in the cord securing feature of the embodiment of FIG. 22 .
FIG. 24A is a detailed view, showing the securing feature used on an electronic device cord and plug.
REFERENCE NUMERALS IN THE DRAWINGS
10
beverage stand
12
receiver
14
cup holder
16
base
18
upright
20
box spring
22
mattress
24
lip
26
holder cutout
28
receiver cutout
30
circular relief
32
notch
34
edge
36
step
38
small portion
40
large portion
42
coffee mug
44
handle
46
can
48
insulating jacket
50
upper surface
52
tumbler
54
notch
56
rib
58
release button
60
base tube
62
extension slide
64
release rod
66
cone shaft
68
compression spring
70
expanding mandrel
72
expansion cone
74
expanding tab
76
slit
78
tube shank
80
through hole
82
retainer
84
cutout flange
86
ladder frame
88
extension slide
90
actuator
92
window
94
flex tang
96
protrusion
98
receptacle
100
support upright
102
receptacle slot
104
large area
106
small area
108
plug
110
cord
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a resting place for a beverage container when the user is not actually holding the beverage container. FIG. 1 shows a preferred embodiment. Beverage stand 10 includes base 16 , upright 18 , and receiver 12 . Upright 18 extends upward from base 16 to any desired height. Receiver 12 is connected to the upper end of upright 18 . Cup holder 14 is attached to receiver 12 .
In some embodiments the cup holder is integral to the receiver itself. However, in the preferred embodiments the cup holder is made removable. The cup holder will accumulate small quantities of spilled liquid over time. The spilled liquid tarnishes the appearance of the device and may in some instances create an unsanitary hazard. Making the cup holder removable allows it to be more easily cleaned—such as by placing it in a dishwasher.
In the embodiment of FIG. 1 , base 16 is elongated so that it may be captured between two elements of a piece of furniture. As an example, FIG. 2 shows the stand with base 16 inserted between box spring 20 and mattress 22 . Upright 18 is preferably made long enough to place receiver 12 well above the upper level of the mattress when the unit is installed. The same method may be used to secure the device to a couch or chair. In that scenario, base 16 is inserted between the cushion and the frame.
Other embodiments may be configured to rest directly on the floor. FIG. 3 shows an embodiment in which base 16 is enlarged in all directions so that it provides stable support when the unit is placed directly on the floor. Upright 18 is sized so that cup holder 14 will rest at the same height as an arm rest or side table.
As stated previously, the preferred embodiments include a removable cup holder. FIG. 4 shows this configuration in more detail. Cup holder 14 is provided with lip 24 which extends over the upward facing surface of receiver 12 . Thus, the cup holder may be lowered into position but it cannot pass completely through the receiver.
The cup holder includes a cutout sized to accommodate the handle of a coffee mug. Holder cutout 26 passes through the vertical side wall of cup holder 14 . Receiver cutout 28 passes through the corresponding portion of receiver 12 . It is preferable to provide a rotation-limiting connection between the cup holder and the receiver so that the two cutouts are aligned when the cup holder is placed in the receiver.
The rotation-limiting connection may assume many forms. FIG. 5 shows an example of such a connection. Receiver 12 includes circular relief 30 which is sized to receiver large portion 40 of cup holder 14 without allowing lip 24 to pass through. The cup holder rests within circular relief 30 but lip 24 bears against upper surface 50 . Circular relief 30 includes one or more notches 32 which are positioned to engage edges 34 on the cutout in the vertical side wall of the cup holder. Thus, when the cup holder is placed in the receiver, the cup holder is unable to rotate with respect to the receiver. In addition, the engagement of the notches with the two edges properly aligns the cutout in the cup holder with the cutout in the receiver.
The size and shape of the cup holder may assume many forms. FIG. 5 shows a version including large portion 40 and small portion 38 . Step 36 lies at the junction between the large portion and the small portion. Step provides a horizontal surface which engages the bottom of a typical coffee mug. On the other hand, the base of a large tumbler will typically be small enough to pass beyond step 36 and into small portion 38 .
FIG. 6 shows the same embodiment with coffee mug 42 in position within the cup holder. The reader will observe how handle 44 protrudes through holder cutout 26 and receiver cutout 28 . The user may grasp the handle and use it to remove the mug from the cup holder or place the mug back in the cup holder. Sufficient clearance is preferably provided on each side of handle 44 to avoid interference between the cup holder and the user's thumb and fingers.
FIGS. 7 and 8 show how the same cup holder geometry can accommodate different types of beverage containers. FIG. 7 shows an aluminum can 46 surrounded by an insulating jacket 48 . This fits within large portion 40 of the sup holder. FIG. 8 shows a large tumbler 52 , the base of which is resting within the small portion of the cup holder.
FIG. 9 shows one possible additional embodiment for the preferred rotation-limiting connection between cup holder 14 and receiver 12 . The cup holder has been provided with a vertical rib 56 sized to slide into notch 54 in the receiver. This engagement easily prevents rotation while maintaining the desired alignment between the cutouts in the cup holder and the receiver.
The invention can be made using a wide variety of materials and need not be made from any single material. As a first example, the base and upright might be made of stamped metal while the receiver and cup holder could be made of injection molded plastic. Likewise, the entire assembly could be made as one unitary piece.
In many installations of the present invention, base 16 will be secured by placing it beneath the mattress of a bed (such as sliding it between a mattress and box spring). It is advantageous to provide an adjustable overall height for the invention in these and other circumstances, so that the user may place the cupholder at a height that he or she desires. FIGS. 10-21 show embodiments in which the distance between the base and receiver is adjustable.
FIGS. 10-16 show a first embodiment incorporating a height adjusting feature. In FIG. 10 base 16 , upright 18 , receiver 12 , and cup holder 14 perform the same functions as the embodiments disclosed previously. Receiver 12 preferably includes receiver cutout 28 . This feature is designed to align with holder cutout 26 in cup holder 14 . However, additional features are provided to allow the adjustment of the height of the device.
The distance between base 16 and receiver 12 is generally fixed when the invention is in use. In order to change the distance, the user presses release button 58 . While continuing to press release button 58 , the user may grasp receiver 12 and pull it upward or push it downward. The mechanism employed preferably allows these operations using only one hand. For example, the user may press release button 58 with the right thumb while simultaneously hooking the fingers of the right hand under receiver 12 and pulling it upward. When the user releases button 58 the receiver will be locked in position.
FIG. 11 graphically illustrates this operation. The upright connecting base 16 to receiver 12 is made of two pieces in this embodiment—base tube 60 and extension slide 62 . The base tube is a hollow extruded tube having a uniform cross section. It is connected via a boss to base 16 at its lower end.
In the embodiment shown, extension slide 62 is another hollow tube. The outside diameter of the tube used for extension slide 62 is selected to be a close sliding fit within the inside diameter of base tube 60 . FIG. 11 shows how a user can press release button 58 and pull receiver 12 upward. Cup holder 14 and extension slide 62 travel along with receiver 12 .
FIG. 12 illustrates how the position of receiver 12 is also rotatably adjustable with respect to base 16 in this particular embodiment. The user is able to grasp receiver 12 and rotate it as indicated by the arrow. Rotation may or may not be locked by the mechanism controlled by release button 58 .
Many different locking mechanisms could be employed in the invention and the invention is certainly not limited to any particular mechanism. Nevertheless, the reader may benefit from an explanation of one particularly suitable locking mechanism and—accordingly—this explanation is provided with respect to FIGS. 13-16 .
FIG. 13 shows an exploded view of the components used in the locking mechanism. Expanding mandrel 70 is attached to the lower end of extension slide 62 . The expanding mandrel and the extension slide slip into the upper end of base tube 60 . It extends below the lower portion of extension slide 62 when installed. Expanding mandrel 70 is changeable between a loaded state in which it expands outward and a relaxed state in which it does not. In the loaded state, the expanding mandrel frictionally engages the inner wall of base tube 60 and locks extension slide 62 to base tube 60 . In the relaxed state, the expanding mandrel is free to move up and down within the base tube and to rotate.
The other components shown (release rod 64 , compression spring 68 , and expansion cone 72 ) are used to control the expanding mandrel. In other words, they selectively change the expanding mandrel between the loaded state and the relaxed state.
Cone shaft 66 is connected to release rod 64 . The cone shaft passes through compression spring 68 and expanding mandrel 70 before attaching to expansion cone 72 .
FIG. 14 shows a more detailed view of the same components. The reader will observe that expanding mandrel 70 has four expanding tabs 74 . Each expanding tab 74 is separated from its neighbors by a pair of slits 76 . The expanding mandrel includes a through-hole along its central axis. This through hole allows the passage of cone shaft 66 . Expansion cone 72 attaches to the end of cone shaft 66 .
Compression spring 68 is sandwiched between expanding mandrel 70 and a shoulder located on release ro6 64 . The compression spring urges the expanding mandrel and release rod apart. In the orientation shown in the view, compression spring 68 urges release rod 64 to the right and expanding mandrel 70 to the left.
Since expansion cone 72 is attached to cone shaft 66 , the effect of compression spring 68 is to pull expansion cone 72 up into the hollow interior of expanding mandrel 70 . The shape of expanding cone 72 thereby urges expanding tabs 74 outward as it is pulled into the interior of the expanding mandrel.
FIGS. 15 and 16 show the expanding mandrel in a loaded state and a relaxed state, respectively. In both views, a “break” is shown in the length of extension slide 62 so that the top and bottom portions can be shown in a single view. In FIG. 15 , the reader will observe how expanding mandrel 70 is attached to the lower portion of extension slide 62 by virtue of tube shank 78 sliding into the open lower end of extension slide 62 (Recall that in this embodiment the extension slide is simply a hollow tube). The mandrel can be attached to the extension slide using adhesive, a threaded engagement, or any other suitable means. Whatever means is used, the upper portion of the expanding mandrel is connected to the lower portion of extension slide 62 .
The expanding mandrel includes a through hole 80 aligned with its central axis. This through hole allows the passage of cone shaft 66 . Expansion cone 72 is connected to the free end of cone shaft 66 . This connection may again be made by adhesive, a threaded engagement, a cross pin, a circlip, etc. However the connection is made, expanding cone 72 is locked securely to cone shaft 66 .
The upper end of the cone shaft is attached to release rod 64 , which slides up and down within extension slide 62 . Compression spring 68 is sandwiched between the downward facing shoulder on release rod 64 and the upward facing surface of tube shank 78 . Expanding mandrel 70 and extension slide 62 are locked together at all times. Thus, compression spring 68 urges release rod upward in the orientation shown in the view. This action urges expansion cone 72 upward. The expansion cone forces expansion tabs 74 outward and causes a strong frictional engagement between the expanding mandrel and the inner wall of base tube 60 . The result is that extension slide 62 is locked in position with respect to base tube 60 .
The reader will also note that the upper portion of extension tube 62 is attached to receiver 12 . A “break” in the view is shown between the lower portion and upper portion of extensions slide 62 and release rod 64 . The break is included so that the upper and lower portions of these components can be shown in the same view at a scale that is large enough to depict the relevant details.
The attachment between the upper portion of extension slide 62 and receiver 12 may again be made by any suitable means, including a press fit, a threaded engagement, an engagement based on adhesive, etc. However the connection is made, extension slide 62 and receiver 12 are locked together.
The upper portion of release rod 64 is also shown in the upper part of FIG. 15 . The very top of release rod 64 includes release button 58 . Receiver 12 preferably includes a retainer 82 surrounding release button 58 . Without the retainer, compression spring 68 would push release rod 64 up and out the top of the receiver. The retainer keeps release rod 64 in the position shown. The retainer is shown as an integral feature of receiver 12 but may of course be a separate feature that is added during the assembly process. It is also possible to omit the retainer altogether, since the interaction of expansion cone 72 and expanding mandrel 70 limits the upward travel of release rod 64 .
FIG. 15 shows expanding mandrel 70 in a “loaded” state. Compression spring 68 is urging expansion cone 70 up into the mandrel and forcing expanding tabs 74 outward. The expanding tabs create a strong frictional engagement with the inward facing wall of base tube 60 . This locks the extension slide and the components attached thereto (receiver 12 and cupholder 14 ) in position.
FIG. 16 shows the locking mechanism in a “relaxed” state. The user has pressed down on release button 58 as indicated by the arrow. This motion pushes release rod 64 downward and pushes expansion cone 72 out of expanding mandrel 70 (while also further compressing compression spring 68 ). Expanding tabs 74 relax inward and are then able to freely slide along the inner wall of base tube 60 . Extension slide 62 is free to slide up and down and to rotate.
Significantly, the mechanism shown allows the user to adjust the position of the receiver 12 using only one hand. Returning to FIG. 11 , those skilled in the art will realize that the user may—using a single hand—depress release button 58 and grasp receiver 12 . While holding the release button down, the user can pull the receiver up or push it down. The user can also rotate the receiver as shown in FIG. 12 . When the user lets go of the release button, the receiver will be locked in position. Thus, the user may adjust the position of the receiver as desired by pressing the release button, moving the receiver to a desired position, and releasing the release button. This feature creates a “selectable separation distance” between receiver 12 and base 16 , which is limited only by the length of base tube 60 and extension slide 62 .
FIGS. 17-21 show still another embodiment incorporating a different type of adjustment mechanism. FIG. 18 shows how the same major components are included—base 16 , upright 18 , receiver 12 , cup holder 14 , and release button 58 . FIG. 18 shows more detail of receiver 12 and cup holder 14 . In the particular embodiment of cup holder 14 shown, holder cutout 26 is preferably aligned with receiver cutout 28 . Holder cutout 26 incorporates a cutout flange 84 surrounding its perimeter. This cutout flange extends outward and bears against the two sides of receiver cutout 28 , thus preventing the rotation of cup holder 14 with respect to receiver 12 .
FIG. 19 illustrates the adjustment features of this embodiment. Ladder frame 86 extends upward from the base. Extension slide 88 is a sliding fit on the ladder frame. Actuator 90 is moved by release button 58 . When the release button is pressed in with respect to receiver 12 , the user is able to move extension slide 88 and up and down with respect to the ladder frame. When the user releases the release button, extension slide 88 is locked into the nearest available position on the ladder frame.
FIG. 20 shows more details of ladder frame 86 , extension slide 88 , and actuator 90 . The reader will note that the ladder frame has a series of transverse windows 92 . The lower portion of actuator 90 includes flex tang 94 . The lower portion of flex tang 94 includes protrusions 96 facing toward the viewer in the view and additional protrusions 96 facing away from the viewer.
When the release button is depressed, actuator 90 moves down with respect to extension slide 88 , and the end of flex tang 94 extends past the end of the extension slide, as shown in FIG. 20 . In this configuration flex tang 94 is free to deflect away from the viewer. This deflection allows the upward facing protrusions 96 to pop in and out of successive windows 92 as extension slide 88 slides with respect to the ladder frame.
However, when the user lets go of the release button, actuator 90 translates upward with respect to extension slide 88 until the lower end of the actuator is roughly even with the lower end of the extension slide. In that position, the rearward facing protrusions 96 bear against the inner wall of actuator 90 and force flex tang 94 to deflect upward. This causes the flex tang to “pop” into the next window 92 it passes. Once the flex tang pops into a window, extension slide 88 is locked in position until the release button is again actuated.
The reader will note in FIG. 20 that two vertical sets of release windows 92 are provided on the ladder frame. These allow the extension slide and its related hardware to be reversible on the ladder frame. The user can depress the release button, pull extension slide 88 completely clear of the ladder frame, rotate the extension slide 180 degrees, and reinstall it. This configuration is shown in FIG. 21 . Thus, the embodiment provides a rotation adjusting feature for the receiver, though it is only possible to place it in two angular positions (0 degrees and 180 degrees).
FIG. 22 shows yet another embodiment of the present invention. Beverage stand 10 includes the primary components described in the embodiments shown in FIGS. 1 - 21 —base 16 , receiver 12 , cup holder 14 , upright 18 , holder cutout 26 , and receiver cutout 28 . FIG. 22 comprises the same basic structure of the invention as the previous embodiments described. In addition, the embodiment shown in FIG. 22 includes many of the additional features shown in FIGS. 10-16 . These features provide the functionality of adjusting the height of beverage stand 10 and rotating receiver 12 , as shown in FIGS. 11-12 .
While beverage stand 10 includes all of the components discussed in the previous text, the embodiment in FIG. 22 also includes additional features. Receiver 12 includes at least one receptacle 98 . Receptacle 98 provides an opening in receiver 12 . Preferably, the opening is located horizontally level with the top surface of receiver 12 . Receptacle 98 includes a bottom surface and 4 side surfaces, thereby creating a pocket. The user can, then, place objects in receptacle 98 in order to hold or store the objects.
In a preferred embodiment of the current invention, there are two receptacles 98 . Each receptacle 98 is preferably designed to fit a multitude of objects. The reader will understand that the user can place many objects in receptacles 98 including a cellular phone, a reading tablet, a book, a television (or any other) remote control, a portable music player, or any object that may fit. Preferably, receptacles 98 do not interfere with holder cutout 26 and receiver cutout 28 . For instance, receptacles 98 can be placed on the opposite end of receiver cutout 28 , proximate push button 58 .
Although two receptacles 98 are shown, the reader should note that there are a number of possible configurations for receptacle 98 . For example, receptacle 98 can be extended in the direction away from cup holder 14 , thereby increasing the width of receptacle 98 . Ultimately, receptacle 98 can take many other forms than shape and size presented here.
Another feature of the embodiment shown in FIG. 22 is support upright 100 . Support upright 100 increases the stability of beverage stand 10 . This is especially true when base 16 is placed between a mattress and box spring (as shown in FIG. 2 ). While in this configuration, support upright 100 is pressed firmly against the side of a mattress, which limits the movement of beverage stand 100 . Preferably, the height of support upright 100 is approximately the thickness of a typical mattress.
FIGS. 23 and 23A show additional details of receptacle 98 . Preferably, the bottom surface of receptacle 98 includes receptacle slot 102 . In an even more preferred embodiment, receptacle slot 102 contains large area 104 and small area 106 . Receptacle slot 102 is designed to accommodate a cord and plug that can be used to charge an electronic device (cellular phone, tablet, portable media player, etc.).
FIGS. 24 and 24A show an electronic device charger within receptacle 98 . Preferably, plug 108 can fit through large area 104 of receptacle slot 102 . In order to keep plug 108 within receptacle 98 , the user can slide cord 110 over into small area 106 of receptacle slot 102 . The cross sectional area of plug 108 is large enough to ensure plug 108 and cord 110 do not fall through receptacle slot 102 . This allows the user to charge an electronic device while it rests in receptacle 98 without concern for plug 108 to fall through receptacle slot 102 .
Although FIGS. 24 and 24A show plug 108 and cord 110 as separate components from receiver 12 , it is possible to provide plug 108 and cord 110 as integral to receiver 12 . In this alternate embodiment, the wire for the charger is attached to upright 18 . This keeps cord 110 stowed and out of the way of the user. Preferably, plug 108 receives power either by battery pack in base 16 or by means of wall outlet. In one configuration, plug 108 is specifically chosen for a type of cellular phone or tablet. However, in a preferred embodiment of the present invention, plug 108 is a standard USB plug. In order to charge a cellular phone or other electronic device, the user can plug in different adaptors for different devices. This is especially useful because the majority of cellular phones, tablets, and portable music players use one of two plugs—an iPhone® type charger plug or a micro-USB type charger plug. It should be noted that other options for plug choice are available, but the most universal choices are discussed.
The preceding description contains significant detail regarding the novel aspects of the present invention. It should not be construed, however, as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. As an example, although the illustrated embodiments show a design incorporating a removable cup holder, the invention could includes an integral cup holder and receiver. Such variations would not alter the function of the invention. Thus, the scope of the invention should be fixed by the following claims, rather than by the examples given. | A beverage container holder adapted to hold a wide variety of containers including cups, bottles, mugs, and tumblers. The device preferably includes a base, an upright extending upward from the base, and a receiver near the top of the upright. The receiver preferably includes a cup holder which is preferably made detachable so that it may be washed in a dishwasher. The height of the receiver with respect to the base is adjustable in the present invention. The rotation of the receiver with respect to the base is preferably also made adjustable. The adjustment mechanism may preferably be activated using only one hand. | 0 |
TECHNICAL FIELD
The present invention relates to an ion generation unit.
BACKGROUND ART
In recent years, there are many electric apparatuses that generate one or both of positive ions and negative ions to obtain effects of germ eradication, deodorization, refreshing and the like. An air conditioner, an air cleaner, a dehumidifier and the like are typical electric apparatuses with which an ion generation apparatus is combined. Some are put in the market as stand-alone ion generation apparatuses.
A traditional method to generate ions is corona discharge. In this method, a high voltage is applied to a discharge body in the atmosphere to produce corona discharge, thereby generating ions electrically. Patent document 1 discloses an example of an ion generation apparatus that uses the corona discharge.
The ion generation apparatus disclosed in the patent document 1 steps up an input voltage from a commercial power supply by means of a voltage step-up apparatus, further transforms it into a drive voltage that has a predetermined drive waveform, then applies it to the ion generation device to generate positive ions and negative ions.
CITATION LIST
Patent Literature
PLT1: JP-A-2006-127855
SUMMARY OF INVENTION
Technical Problem
According to its operation principle, an ion generation apparatus requires switching at a high voltage and cannot evade occurrence of a radiant noise caused by the switching. As anti-radiant-noise measures, the following measures are employed:
(a) Lowering the peak value of an ion generation voltage of the ion generation apparatus. (b) Enclosing a voltage step-up transformer with a shield case. (c) Attaching an adhesive tape (hereinafter “metal-foil tape” in the present specification) containing a metal (usually aluminum) foil as a component, to an outer surface of the ion generation device.
In the ion generation apparatus disclosed in the patent document 1, a measure mainly following the lead of above measure (b) is adopted. Namely, a copper tape, a kind of metal-foil tape, is wound around a voltage step-up coil, and a shield case formed of a tin plate is disposed around the voltage step-up coil to curb occurrence of a radiant noise.
According to the above measure (a), a voltage applied to a discharge body declines and it becomes hard to generate intended amount of ions. Also the measure (b) has the same problem as the measure (a) that the voltage applied to the discharge body declines. This is because a discharge occurs between a secondary terminal of the voltage step-up transformer and the shield case.
In a case of taking the above measure (c), a degree of radiant noise curbing changes depending on the manner how the metal-foil tape is attached. It is possible to look for, through trial and error, a way of metal-foil tape attachment that curbs the radiant noise and does not reduce the amount of generated ions so much. However, this method requires preparation of ion generation devices, to which the metal-foil tape has been attached, as service parts. Besides, an acceptable level of radiant noise depends on the type of electric apparatuses into which the ion generation device is incorporated, and it is necessary to provide, as service parts, many kinds of ion generation devices having the metal-foil tape attached in different ways.
The present invention has been made in light of the above points, and it is an object to provide an ion generation unit that reduces a radiant noise to improve the reliability of a product without reducing an amount of generated ions, and further does not require many kinds of ion generation devices as service parts.
Solution to Problem
An ion generation unit according to the present invention includes: an ion generation device that generates ions by voltage application; and a casing that houses the ion generation device; wherein an inner surface of the casing is provided with a curbing member that curbs a radiant noise caused by ion generation.
In the ion generation unit having the above structure, it is preferable that the casing is provided with an opening portion that discharges the ions generated from the ion generation device to outside, and a portion other than the opening portion is provided with the curbing member.
In the ion generation unit having the above structure, it is preferable that the curbing member is composed of a metal plate.
In the ion generation unit having the above structure, it is preferable that the curbing member is composed of an adhesive sheet that contains a metal foil as a component.
Advantageous Effects of Invention
According to the present invention, the inner surface of the casing that houses the ion generation device is provided with the curbing member that curbs the radiant noise: accordingly, it is possible to reduce the radiant noise without reducing an amount of generated ions. Besides, the ion generation device is not modified: accordingly, it is unnecessary to prepare many kinds of the ion generation devices as service parts.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a front view of an ion generation unit according to an embodiment of the present invention.
FIG. 2 is an exploded perspective view of components.
FIG. 3 is a perspective view of an ion generation unit in an assembled state to which a rear lid is ready to be fitted.
FIG. 4 is a sectional view of an ion generation unit.
DESCRIPTION OF EMBODIMENTS
An ion generation unit 1 as an embodiment of the present invention is designed as a unit to be incorporated in other apparatuses such as, for example, an indoor unit of an air conditioner, an air cleaner, a car and the like. The ion generation unit 1 includes a synthetic resin casing 10 that has a shape of a small-sized indoor unit of an air conditioner and is laterally long. The casing 10 includes a casing main body 11 and a rear lid 12 (see FIG. 3 ). The rear lid 12 is visible from a rear side only, and when viewed from a front side, the casing main body 11 makes up an entire appearance. In the meantime, an upper side and a lower side of FIG. 1 correspond to an upper side and a lower side of the ion generation unit 1 , respectively, and a left side and a right side of FIG. 1 correspond to a left side and a right side of the ion generation unit 1 , respectively. This orientation also applies to other components.
An ion generation device 20 is housed in the casing 10 . The ion generation device 20 has a rectangular parallelepiped shape. When applied a predetermined voltage to the ion generation device 20 , the ion generation device 20 generates ions by corona discharge. The ion generation device 20 is able to generate positive ions H + (H 2 O) m (m is an arbitrary natural number) and negative ions O 2 − (H 2 O) n (n is an arbitrary natural number) concurrently.
The casing main body 11 is provided with opening portions at a position near the left end and at a position near the right end, through both of which ions generated by the ion generation device 20 are discharged. The positions of the opening portions correspond to positions of ion generation portions (not shown) of the ion generation device 20 . Both the left opening portion and the right opening portion are formed by arranging an opening portion 13 that extends from the front surface to an upper surface of the casing main body 11 and an opening portion 14 that extends from the upper surface to a lower surface of the casing main body 11 vertically. The opening portions 13 , 14 are provided with sets of a plurality of vertical crosspieces at predetermined intervals that prevent foreign matter from entering the casing 10 . Crosspieces 13 a are arranged at relatively narrow intervals in the opening portion 13 while crosspieces 14 a are arranged at relatively wide intervals in the opening portion 14 .
As shown in FIG. 2 , the casing main body 11 is placed on an assembly table or the like with the front surface thereof down and the rear opening thereof, into which the rear lid 12 is fitted, up. The ion generation device 20 is inserted into the casing main body 11 through the rear opening. A power supply cable 21 is connected to the ion generation device 20 . The power supply cable 21 has connectors 22 , 23 at both ends. The connector 22 is to be connected to the ion generation device 20 , while the connector 23 is to be connected to an external power supply cable (not shown). The connector 23 is fixed to the casing main body 11 by means of a screw 24 .
As shown in FIG. 3 , when the rear lid 12 is fitted with the ion generation device 20 and the power supply cable 21 set in the casing main body 11 , the ion generation unit 11 reaches completion. As to the rear lid 12 , a surface facing an inside of the casing 10 is provided with two stripes of protrusions 15 , 16 that go into an internal space of the casing main body 11 . Both protrusions 15 and 16 extend in a horizontal direction. The protrusion 15 is formed at a position that is lower than an upper edge of the rear lid 12 by a thickness of an outer shell of the casing main body 11 , while the protrusion 16 is formed at a position that is higher than a lower edge of the rear lid 12 by the thickness of the outer shell of the casing main body 11 .
An upper surface of the protrusion 15 and a lower surface of the protrusion 16 are each provided with a plurality of engagement protrusions 17 . In the embodiment, the protrusion 15 is provided with four engagement protrusions 17 , and also the protrusion 16 is provided with four engagement protrusions 17 at an equal interval. In the meantime, the number “four” defining protrusion quantity is a mere example and does not limit the invention. The casing main body 11 is provided with a plurality of engagement holes 18 at positions corresponding to the engagement protrusions 17 .
When the rear lid 12 is placed on the casing main body 11 in the state of FIG. 3 and a downward force is exerted on the rear lid 12 , the engagement protrusion 17 engages with the engagement hole 18 to go to a state shown in FIG. 4 . In this state, protrusions 19 formed at some positions of an inner surface of the rear lid 12 push down the ion generation device 20 , whereby the ion generation device 20 is firmly fixed.
An inner surface of the casing 10 is provided with a curbing member that curbs a radiant noise caused by the ion generation. The curbing member can be composed of a metal plate. The metal plate can be fixed to the casing 10 by means of an adhesive, a double-faced adhesive tape, a screw or the like.
The curbing member can be composed of an adhesive sheet that contains a metal foil, an aluminum foil for example, as a component. Such a curbing member is easy to mount. If the adhesive sheet is formed into a roll of adhesive tape, it becomes easy to handle.
It is preferable to mount the curbing member on both the casing main body 11 and the rear lid 12 . FIG. 2 shows a state where the curbing member is mounted on an inner surface of the casing main body 11 . The curbing member 30 is mounted on a flat inner surface between the left and right opening portions 13 , 14 , the curbing member 31 is mounted on a lower inner surface, and the curbing member 32 is mounted on a left inner surface. A curbing member, which pairs with the curbing member 31 , is mounted on an upper inner surface that is hidden in FIG. 2 . Likewise, a curbing member, which pairs with the curbing member 32 , is mounted on a right inner surface that is hidden in FIG. 2 .
FIG. 3 shows a state where a curbing member is mounted on the inner surface of the rear lid 12 . The curbing member 33 covers a flat portion between the protrusions 15 , 16 .
As described above, the curbing members 30 , 31 , 32 , and 33 are mounted on the inner surface of the casing main body 11 : accordingly, it is possible to reduce the radiant noise without mounting a curbing member on the ion generation device 20 . The curbing members 30 , 31 , 32 , and 33 are mounted on places other than the opening portions 13 , 14 : accordingly, discharge of the ions through the opening portions 13 , 14 is not discouraged, i.e. an amount of discharged ion is not reduced.
The ion generation device 20 is not modified: accordingly, it is unnecessary to prepare many kinds of the ion generation devices 20 as service parts. In other words, the ion generation device 20 is standardizable.
In various apparatuses that incorporate the ion generation unit 1 , the structure of a holder that holds the ion generation unit 1 is unique to each apparatus. However, even if an apparatus is modified, as long as the holder structure is the same, the same ion generation unit 1 is incorporable. In other words, the same ion generation device 20 as a standard service part is usable.
Hereinbefore, the embodiment of the present invention is described. However, the scope of the present invention is not limited to the embodiment, and various modifications can be made if the modifications do not depart from the spirit of the invention.
INDUSTRIAL APPLICABILITY
The present invention is widely applicable to ion generation units.
REFERENCE SIGNS LIST
1 ion generation unit
2 casing
11 casing main body
12 rear lid
13 , 14 opening portions
20 ion generation device
30 , 31 , 32 , 33 curbing members | An ion generation unit ( 1 ) provided with an ion generation element ( 20 ) for generating ions through application of voltage, and a casing ( 10 ) housing the ion generation element. The casing is constituted by a casing body ( 11 ) and a rear cover ( 12 ). To the inside face of the casing are attached suppressing members ( 30, 31, 32, 33 ) for suppressing the radiation noise associated with ion generation. Openings ( 13, 14 ) through which the ions generated by the ion generation element are emitted to the outside are formed in the casing body, and the suppressing members are attached at locations other than the openings. | 5 |
TECHNICAL FIELD
This invention relates generally to hand tools, and more particularly to wrenches for rotating a fastener.
BACKGROUND
Attempts have been made to eliminate the need for multiple length socket sets in ratchet wrench design without sacrificing structural integrity, reliability or ease of use. Early attempts focused on designs of ratchet wrenches having a hole through the wrench centered on the axis of rotation of the drive portion of the ratchet wrench. U.S. Pat. No. 125,695 to Sanborn, U.S. Pat. No. 1,165,995 to Mossberg and U.S. Pat. No. 2,317,461 all disclose a ratchet wrench with a through hole. The wrench in each of these patents is adapted for only a single fastener size. U.S. Pat. Nos. 1,347,691 to Forton, 4,328,720 to Shiel, and 2,300,479 to Wilson each discloses a ratchet wrench with a through hole which is adapted for using interchangeable sockets enabling the use of the wrench with a range of fastener sizes. U.S. Pat. Nos. 4,520,697 and 4,602,534 to Moetteli disclose a ratchet wrench having a through hole and which is adapted for use with multiple sockets. The later two patents to Moetteli disclose a reversible ratchet wrench which eliminates the need for multiple length socket sets through the use of special sockets which are comparable to the weight, compactness, strength and size range of standard square drive sockets. Though the latter two patents describe an invention which overcomes most of the disadvantages and shortcomings characteristic of the earlier through-hole designs, it is not successful in duplicating the retention force typical of a standard ratchet wrench's spring-and-ball detent without a concomitant sacrifice in structural integrity.
Proper retention of a socket is an important feature of wrenches because it prevents the inadvertent disengagement of the socket from the drive portion of the wrench. Inadvertent disengagement can result in extreme inconvenience for several reasons. First, the socket may become much more difficult to position over the fastener if it is not held in place on the drive and maneuvered by the operator's hand remotely through the ratchet wrench's handle. Second, the socket may become lost in some remote recess, or become temporarily unretrievable due to its becoming lodged in a recess near a very hot component of an automotive engine thus making safe retrieval difficult. Third, although the operator may be able to successfully remove the ratchet, the socket may remain on the fastener thereby becoming difficult or impossible to remove without expending excessive time to do so. Fourth, due to their additional weight, the ratchet may not be able to adequately retain commonly used accessories on the drive member such as a universal joint or extension; this will result in still more difficulty in accessing a fastener for removal or installation. Fifth, the socket may slip off the drive during wrenching with the possible result being damage to the ratchet or socket and/or injury to the operator.
In standard ratchet wrenches adapted for use with a socket set, it is common to provide a spring-and-ball detent to secure the socket on the drive member of the wrench during use. Generally, this has provided adequate retention such that the five problems mentioned above can be avoided. Characteristic of a spring-and-ball detent is the requirement of a relatively thick section on the drive member in order to accommodate the enclosure the spring and the ball. However, because a thin-wall is created in the drive portion when the wrench has a through hole and (1) has an inner and outer drive or (2) has a drive portion which protrudes beyond the drive member of the wrench, there is insufficient material to support this conventional means for retaining a socket on the drive.
U.S. Pat. No. 2,549,515 to Orey et al describes a thin-wall through-hole wrench that utilizes resilient members disposed within a key-way type recess in the thin-wall sleeve to restrain the sockets onto the sleeve or drive portion. These resilient members provide adequate retention of the sockets onto the sleeve; however, the resilient member and key-way recess retain a socket from one side of the drive portion only, not from both surfaces of the drive portion as provided in the present invention. Also, no means is described for the mounting of the resilient member onto the drive portion. In the invention as described in U.S. Pat. No. 4,328,720 to Shiel, the means provided for retaining a socket was that of a resilient annular wire disposed within the thin-wall portion of the drive member. This too may provide adequate retention of a socket, but it also requires that a recess be machined into the drive portion in which the wire may be disposed. This recess weakens the drive portion as it lies within a plane substantially perpendicular to the torsional axis of the wrench.
The hand tool described in U.S. Pat. No. 1,413,698 to Adams discloses a spring clip formed of a resilient strip of metal. This clip is designed to hold shanks or sockets within the drive portion. It would therefore be ineffective for retaining sockets either on the outside or the inside of the drive portion. In addition, the spring clip requires that a reduced thickness portion be machined or molded onto the thin-wall portion of the drive member. This reduced thickness portion compromises the structural integrity of the drive portion against torsional stresses induced through normal operation of the hand tool.
The swivel knife described in U.S. Patent No. 2,803,877 to Belanger discloses a V-shaped retainer spring for the purpose of retaining an internal tool shank and an outer collar. This retainer spring does not function independently but requires a cylindrical component referred to as a locking means in order to retain the tool shank inside the stud.
The ratchet wrenches described in U.S. Pat. Nos. 4,520,697 and 4,602,534 to Moetteli above recites incorporate several methods for retaining a socket to a drive member having a thin-wall drive portion. A first method incorporates a push-button release feature which allows the operator to remove a socket by depressing a resilient button or comparable element. A second method utilizes a resilient spring clip which snaps in place over the thin-wall portion of the drive member in a manner similar to a paper clip. However, the first method utilizes a spring which is relatively complicated and costly to produce and the second method utilizes a spring clip that requires that a reduced thickness portion be machined or molded onto the thin-wall portion of the drive member. Furthermore, this spring clip is unsatisfactory as it frequently breaks due to its thin cantilevered construction or fails to properly hold the socket in place due to a limitation in the amount of spring force and friction that can be generated when deflected. This limitation on spring force is due to the necessity that the spring clip be made of thin material in order to wrap around the reduced thickness portion while remaining flush with the outer and inner surfaces of the drive member in the area of the reduced thickness portion. The thicker the spring is, the thinner the reduced thickness portion must be and consequently, the weaker the structure of the drive member becomes. In addition, the reduced thickness portion is complicated, relatively costly to produce, and detrimental to the structural integrity of the drive member.
A need therefore exists for an improved socket retainer which can reduce manufacturing costs and increase the amount of frictional force with which to securely hold a socket on a through-hole wrench having an inner and outer drive portion without unduly diminishing the structural integrity of the wrench.
SUMMARY
My invention is directed to an improved retainer for a ratchet wrench having a thin-wall drive member that satisfies the needs identified above.
In accordance with one embodiment of the present invention, I have invented an improved ratchet wrench for rotating a fastener. The ratchet wrench includes a handle having a head at one end thereof, the head having a cylindrical aperture formed therethrough centered on an axis. A drive member is mounted onto the handle and extends into the cylindrical aperture for rotation about the axis relative to the handle. The drive member is operably connected to a fastener so that rotation of the drive member rotates the fastener. The drive member further defines another aperture extending therethrough along the axis. This drive member has a drive portion with inner and outer surfaces extending along a common axis, the outer surface of the drive portion having a non-circular cross section perpendicular to the common axis and adapted for receiving a socket, and the inner surface of the drive portion having a non-circular cross section perpendicular to the common axis and adapted for receiving a socket. An elongated slot is formed through the inner and outer surfaces of the drive member. This elongated slot has opposite ends and at least one internal flange portion formed adjacent to the internal surface within the elongated slot such that a projection is formed at each end of the elongated slot. A resilient s-shaped spring is disposed within the elongated slot and is held in place by deforming an edge against each end of the resilient spring. This edge is defined by the intersection of the outer surface and the elongated slot. This deforming operation effectively sandwiches the spring ends between the deformed edge and each projection while still allowing the middle portion of the spring to flex. Each wave of the s-shaped spring is sized to protrude beyond the elongated slot and either into the aperture or out of the drive member such that a socket will necessarily deflect the corresponding wave of the s-shaped spring when fully engaged on the drive. This deflection of the resilient spring enables the frictional retention of the socket on the drive member. Furthermore, the thickness of the spring is not limited in that it need not wrap around the drive member and therefore does not locally increase the width of the drive portion or create a structurally weak region in the drive portion as is evident when considering a cross section through the drive member in an area between the furthermost end of the elongated slot and the end of the drive portion (in this region, the drive portion remains of consistent thickness). In this embodiment, the thickness of the spring is limited by the thickness of the drive portion minus the sum of the thickness of the flange and the thickness of the deformed edge of the elongated slot (the thicker the spring, the stronger the socket retention force of the spring). In addition, a recess or recesses may be provided in the socket to enable more positive engagement of the socket when fully engaged on the drive portion.
In accordance with another embodiment of the present invention, I have invented an improved ratchet wrench for rotating a fastener. The ratchet wrench includes a handle having a head at one end thereof, the head having a cylindrical aperture formed therethrough centered on an axis. A drive member is mounted onto the handle and extends into the cylindrical aperture for rotation about the axis relative to the handle. The drive member is operably connected to a fastener so that rotation of the drive member rotates the fastener. The drive member further defines another aperture extending therethrough along the axis. This drive member has a drive portion with inner and outer surfaces extending along a common axis, the outer surface of the drive portion having a non-circular cross section perpendicular to the common axis and adapted for receiving a socket, and the inner surface of the drive portion having a non-circular cross section perpendicular to the common axis and adapted for receiving a socket. An elongated slot is formed through the inner and outer surfaces of the drive member. This elongated slot has opposite ends and at least one internal flange portion formed adjacent to the internal surface within the elongated slot such that a projection is formed at each end of the elongated slot. Opposed resilient members are mounted in the elongated slot facing opposite one another and held in place by deforming an edge against the ends of the resilient members. This edge is defined by the intersection of the outer surface and the elongated slot. This deforming operation effectively sandwiches the spring ends between the deformed edge and each projection while still allowing the middle portion of each spring to flex. Each opposed resilient member has a middle portion corresponding in shape to the elongated slot and having at least one protrusion which projects beyond the confines of the elongated slot, thereby enabling the protrusion to frictionally engage a socket by resiliently deflecting the protruding portion relative to the drive portion. For the same reasons stated above, the drive portion maintains its structural integrity as a cross section taken between the furthermost end of the elongated slot and the end of the drive portion yields a cross section of consistent thickness. In addition, the thickness of each spring is limited only by the thickness of the drive portion minus the sum of the thickness of the opposed spring, the thickness of the flange and the thickness of the deformed edge of the elongated slot. Although this embodiment does not allow each opposed spring to be as thick as compared with the embodiment utilizing a single s-shaped spring, each opposed spring reacts against the other thereby providing for a higher socket retention force than would be expected from a single thin spring.
The design of both the s-shaped and opposed resilient member permits ease of fabrication and subsequent installation in the elongated slot. Because of their simple form, these resilient members can be stamped using conventional methods with simple tooling. After fabrication, the spring or springs need only be placed within the confines of the slot and staked into place using a tool, such as a center punch, capable of deforming the outside edge of the elongated slot. At least two methods may be used in deforming the edge in order to sandwich the spring or springs in place. First, localized deformation can take place at the ends of the elongated slot. Localized deformation at the ends of the slot enables the spring or springs to have a uniform width if installed in a suitable elongated slot. Second, the entire edge of the elongated slot can be deformed. If this is done, the portion of the spring which protrudes beyond the slot and out of the drive portion may be required to have a reduced width (as compared to the spring ends) in order to avoid binding of the spring between the deformed edges.
In addition, the slot is relatively simple to manufacture. One method for making an elongated slot in which the resilient member can effectively function is to use a single end-mill tool of uniform size. A second method for producing the elongated slot is to use a stepped end-mill having two cutting diameters, the first to contact the drive portion in the cutting operation being the smaller diameter. A third method for producing the elongated slot is substantially the same as the second method except that instead of using one stepped end-mill, two end-mills of uniform but different diameters are used in two separate machining passes. Generally, the second and third method for generating the elongated slot result in a continuous lip or projection being formed adjacent to the inner surface of the drive portion and inside the elongated slot. This may effect the shape of a resilient spring (e.g. make it dog-bone shaped) in that the portion of a spring which protrudes into the aperture cannot be wider than the opening between the lips of the slot. A fourth method for producing the slot is through molding or casting the slot in place. This method significantly reduces or eliminates any secondary machining of the slot. Also, because of the shape of the slot--one which does not have any undercuts or blind cavities--a single mold insert can easily be fabricated to accomplish this end.
DESCRIPTION OF THE DRAWINGS
Other objects and advantages of this invention will become readily apparent as the same is better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
FIG. 1 shows a cutaway view of a ratchet wrench with a socket for rotating a fastener;
FIG. 2a shows a front view of the elongated slot in the drive portion of the drive member of the ratchet wrench;
FIG. 2b shows a side cross sectional view of the elongated slot in the drive portion of the drive member of the ratchet wrench;
FIG. 3a shows a side cross sectional view of the elongated slot after installation of an s-shaped spring in the slot and with a socket inserted into the drive portion of the ratchet wrench according to the teachings of the first embodiment of the invention; and
FIG. 3b shows a side cross sectional view of the elongated slot after installation of two opposed resilient members according to the teachings of the second embodiment of the invention.
FIG. 3c shows a front view of the elongated slot after installation of the resilient member or members and deformation of the edge of the slot.
DETAILED DESCRIPTION
Referring now to the drawings wherein is shown preferred embodiments and wherein like reference numerals designate like elements throughout the several views, there is shown in FIG. 1 a cutaway view of a ratchet wrench 20 for rotating a fastener 22. The ratchet wrench includes a handle 24 having a head 26 at one end thereof, the head having a cylindrical aperture formed therethrough centered on an axis 28. A drive member 30 is mounted onto the handle and extends into the cylindrical aperture for rotation about the axis relative to the handle. The drive member is operably connected to the fastener so that rotation of the drive member rotates the fastener. The drive member further defines another aperture 32 extending therethrough along the axis. This drive member has a drive portion 34 with an inner surface 36 and an outer surface 38 extending along a common axis 28, the outer surface of the drive portion having a non-circular cross section perpendicular to the common axis and adapted for receiving a socket 40a, and the inner surface of the drive portion having a non-circular cross section perpendicular to the common axis and adapted for receiving a socket 40b, this socket being shown in the cross sectional view of FIG. 3a. An elongated slot 50 most clearly depicted in FIGS. 2a and 2b is formed through the inner and outer surfaces of the drive member. This elongated slot has opposite ends 52 and 54 and at least one internal flange portion 56 formed adjacent to the internal surface within the elongated slot such that a first and second projection 58 and 60 is formed at each end of the elongated slot.
In accordance with one embodiment of the present invention as depicted in FIGS. 3a and 3c, a resilient s-shaped spring 62 formed from flat spring material is disposed within the elongated slot and is held in place by deforming an edge 64 against the first and second end 66a and 68a of the resilient spring. This edge is defined by the intersection of the outer surface and the elongated slot. This deformation effectively sandwiches the spring ends between each deformed edge 72 and 74 and each projection while still allowing the middle portion 76a of the spring to flex. Curved portions 78a and 80a of the s-shaped spring are sized to protrude beyond the elongated slot and either into the aperture 32 or out of the drive member such that a socket will necessarily deflect the corresponding wave of the s-shaped spring when fully engaged on the drive portion. This deflection of the resilient spring enables the frictional retention of the socket on the drive member. At least one recess 82a or 82b may be provided in a socket to more positively engage the socket when the socket is fully engaged on the drive portion. Furthermore, the thickness of the spring is substantial in that it need not wrap around the drive member and therefore does not locally increase the width of the drive portion or create a structurally weak region in the drive portion as is evident by taking a cross section through the drive member in an area between the furthermost end of the elongated slot and the end of the drive portion (the drive portion remains of consistent thickness). The thickness of the spring is limited only by the thickness of the drive portion minus the sum of the thickness of the flange and the thickness of the deformed edge of the elongated slot.
In accordance with another embodiment of the present invention as depicted in FIG. 3b and 3c, opposed resilient members 84a and 84b formed from flat spring material are mounted in the elongated slot facing opposite one another and held in place by deforming an edge 64 against the ends 66b, 66c, 68b, and 68c of the resilient members. This edge is defined by the intersection of the outer surface of the drive portion and the elongated slot. This deformation effectively sandwiches the spring ends between each deformed edge 72 and 74 and each projection while still allowing the middle portion of each spring to flex. Each opposed resilient member has a middle portion 76b and 76c corresponding in shape to the elongated slot and having at least one protrusion 78b and 8Ob which projects beyond the confines of the elongated slot, thereby enabling the protrusion to frictionally engage a socket by resiliently deflecting the protruding portion relative to the drive portion. For the same reasons stated above, the drive portion maintains structural integrity as a cross section taken between the furthermost end of the elongated slot and the end of the drive portion has a consistent thickness. Furthermore, the thickness of each spring is limited only by the thickness of the drive portion minus the sum of the thickness of the opposed spring, the thickness of the flange and the thickness of the deformed edge of the elongated slot. Therefore, the use of the opposed resilient members reduces the maximum thickness permissible for each opposed resilient member as compared to the use of a single s-shaped resilient member above (by an amount equal to the thickness of the opposed resilient member). However, because the two opposed resilient members are sandwiched together, they are able to react against one another thereby significantly increasing the resistance of the assembly to deflection and therefore the force with which it can retain a socket.
The design of the resilient member permits ease of fabrication from a suitable spring material such as high-carbon steel and ease of installation in the elongated slot. A simple stamping operation is all that is necessary to form the s-shaped spring or either of the opposed springs. For assembly in the elongated slot, the spring or springs need only be installed within the confines of the slot and staked into place using a tool, such as a center punch, capable of deforming the outside edge of the elongated slot. At least two deformation methods may be used in deforming the edge in order to sandwich the spring or springs in place. The first deformation method results in an assembly generally as shown in FIG. 3c. In this method, the ends of the elongated slot are locally deformed using a suitable tool such as a center punch which results in a plurality of dimples 90, or a special punch which corresponds in shape to the edge to be deformed. Localized deformation at the ends of the slot enables the spring to have a uniform. width which corresponds to the width of the middle portion of the slot as shown in FIGS. 2a and 3c. In the second method, the entire edge of the elongated slot is deformed. If this is done, the width of the portion of the spring which protrudes beyond the slot and out of the drive portion must be reduced (as compared to the width of the spring ends) in order to avoid the binding of the spring between the deformed edges. Furthermore, it should be noted that in both methods of deforming the edge over the ends of the spring or springs, it is not necessary that the ends be held such that they cannot move in the slot. The deformation of the edge is only meant to prevent lateral movement of the spring or springs relative to the axis 28 and to retain the spring or springs within the elongated slot, particularly when the spring or springs are deflected by a socket. Other methods, though not preferred, are contemplated as being effective for securing the spring or springs in the elongated slot. These include spot welding, fastening with rivets or screws, or brazing.
In addition, the elongated slot is relatively simple to manufacture. A first method for making the elongated slot of the configuration as described in FIGS. 2a and 2b, is to use a single end-mill tool of uniform size. The end-mill tool can be plunged into the drive portion of the drive member in a direction perpendicular to its outer surface, then stopped before exiting through the inner surface, redirected to travel a distance along the length of the drive portion and parallel with the axis 28 of the aperture in the drive member, stopped again, redirected to break through the inner surface of the drive portion, stopped, redirected to continue along the length of the drive portion thereby creating a slot through the drive portion, stopped, redirected to partially back out of the slot so created, stopped, redirected to continue along the length of the drive portion, stopped, and backed out of the resulting elongated slot. An alternative using the same end-mill of uniform size would involve taking two passes, the first creating a larger blind slot and the second breaking through the thin wall of the drive portion and creating a slot of lesser length than the first and centered within the larger slot.
A second method for producing the elongated slot is to use a stepped end-mill having two cutting diameters, the first to contact the drive portion in the cutting operation being the smaller diameter. This stepped end-mill tool can be plunged into the drive portion in a direction perpendicular to its outer surface until just before the second larger diameter exits through the inner surface, then stopped, redirected along the length of the drive portion and parallel with the axis 28, stopped again and backed out of the slot so created.
A third method for producing the elongated slot is substantially the same as the second method except that instead of using one stepped end-mill, two end-mills of uniform diameter are used in two separate passes. Generally, the second and third method for generating the elongated slot result in a continuous lip or projection being formed adjacent to the inner surface of the drive portion and inside the elongated slot. This may effect the shape of a resilient spring (e.g. make it dog-bone shaped) in that the portion of a spring which protrudes into the aperture cannot be wider than the opening between the lips of the slot.
A fourth method for producing the slot is through casting or molding the slot in place thereby significantly reducing or eliminating any secondary machining of the slot completely. Because of the shape of the slot, one which does not have any undercuts or blind cavities, a single mold insert can easily be fabricated to accomplish this end.
Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. For example, the elongated slot may have squared ends or some shape other than the rounded ends depicted in the drawings. The ratchet wrench described herein may have other additional features common to ratchet wrenches such as reversibility, fine-tooth ratchet action, a thumb-wheel and the like. Also, other shapes for the resilient members are possible besides the s-shaped and bowed shapes described herein. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. | This invention relates to an improved socket retainer device for a thin-wall drive portion of a wrench having an inner and outer drive portion. A resilient spring is placed within an elongated slot which is machined in the drive portion of the wrench. The outer edge of the slot is deformed such that the resilient spring is held firmly in place at its ends, the middle portion of the resilient spring being allowed to deflect and frictionally engage sockets when the socket is attached to the drive portion of the wrench. One embodiment of the present invention defines an s-shaped resilient spring and another defines two opposed resilient springs. The design results in lower fabrication and assembly costs and improved socket retention ability without compromising the strength of the drive portion of the wrench. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a Continuation-in-Part application that claims benefit under 35 U.S.C. §120 to application Ser. No. 10/674,268, filed Sep. 29, 2003, entitled “Solubilized CoQ-10”, the contents of which are incorporated herein in their entirety for all purposes.
FIELD OF THE INVENTION
The present invention relates to the solubilization of coenzyme Q-10 and analogs thereof in monoterpenes, thereby providing increased bioavailability in delivery.
BACKGROUND OF THE INVENTION
CoQ-10 (coenzyme Q10) is a fat-soluble quinone that is structurally similar to vitamin K and commonly known as ubiquinone. CoQ-10 is found in most living organisms, and is essential for the production of cellular energy. CoQ-10 (2,3 dimethyl-5 methyl-6-decaprenyl benzoquinone) is an endogenous antioxidant found in small amounts in meats and seafood. Although CoQ-10 is found in all human cells, the highest concentrations of CoQ-10 occur in the heart, liver, kidneys, and pancreas. It is found naturally in the organs of many mammalian species.
CoQ-10 can be synthesized in the body or it can be derived from dietary sources. Situations may arise, however, when the need for CoQ-10 surpasses the body's ability to synthesize it. CoQ-10 can be absorbed by oral supplementation as evidenced by significant increases in serum CoQ-10 levels after supplementation.
CoQ-10 is an important nutrient because it lies within the membrane of a cell organelle called the mitochondria. Mitochondria are known as the “power house” of the cell because of their ability to produce cellular energy, or ATP, by shuttling protons derived from nutrient breakdown through the process of aerobic (oxygen) metabolism. CoQ-10 also has a secondary role as an antioxidant. CoQ-10, due to the involvement in ATP synthesis, affects the function of almost all cells in the body, making it essential for the health of all human tissues and organs. CoQ-10 particularly effects the cells that are the most metabolically active: heart, immune system, gingiva, and gastric mucosa
Several clinical trials have shown CoQ-10 to be effective in supporting blood pressure and cholesterol levels. Furthermore, CoQ-10 has also been shown to improve cardiovascular health. CoQ-10 has been implicated as being an essential component in thwarting various diseases such as certain types of cancers. These facts lead many to believe that CoQ-10 supplementation is vital to an individual's well being.
CoQ-10 is sparingly soluble in most hydrophilic solvents such as water. Therefore, CoQ-10 is often administered in a powdered form, as in a tablet or as a suspension. However, delivery of CoQ-10 by these methods limits the bioavailability of the material to the individual.
There is a need in the art for an improved methodology to deliver increased amount of bioavailable CoQ-10 to an individual in need thereof.
BRIEF SUMMARY OF THE INVENTION
The present invention pertains to the surprising discovery that ubiquinone (CoQ-10) and related analogs thereof can be readily dissolved in varying concentrations in monoterpenes. Generally, until the present discovery, most CoQ-10 liquid delivery methods could solubilize only up to about 5% by weight of the CoQ-10 in the “solvent”. Typical solvents included various oils or the CoQ-10 was held in suspension. The present invention provides the ability to solubilize CoQ-10 in monoterpenes in concentrations of up to about 60% (weight to weight) without the need to aggressively heat the solution or with gentle warming. In particular, the solubilization of the CoQ-10 with monoterpenes can be accomplished at ambient temperatures.
In one aspect, the present invention pertains to compositions that include coenzyme Q-10 or an analog thereof with a sufficient quantity of a monoterpene that is suitable to solubilize said coenzyme Q-10 and a pharmaceutically acceptable carrier. Generally, about 30 to about 45% of the CoQ-10 (by weight) is solubilized in the monoterpene. In particular, the monoterpene is limonene. The compositions of the invention are useful as dietary supplements or as nutriceuticals.
In particular, the compositions of the invention are included in a soft gelatin (soft gel) capsule. Typically, the soft gelatin capsule includes at least 5% by weight of coenzyme Q-10 or an analog thereof solubilized in a monoterpene. Typical monoterpenes include, for example, perillyl alcohol, perillic acid, cis-dihydroperillic acid, trans-dihydroperillic acid, methyl esters of perillic acid, methyl esters of dihydroperillic acid, limonene-2-diol, uroterpenol, and combinations thereof.
In another embodiment, the present invention pertains to methods for delivery of an effective amount of bioavailable CoQ-10 to an individual. The method includes providing CoQ-10 solubilized in a monoterpene, such that an effective amount of CoQ-10 is provided to the individual.
In still another embodiment, the present invention also includes packaged formulations of the invention that include a monoterpene as a solvent for the CoQ-10 and instructions for use of the tablet, capsule, elixir, etc.
In one aspect, the present invention provides solubilized coenzyme Q-10 compositions that include coenzyme Q-10 or an analog thereof, a sufficient quantity of a monoterpene suitable to solubilize said coenzyme Q-10 or analog thereof, and an acceptable carrier. The compositions provide a percentage of coenzyme Q-10 dosage that is absorbed by an individual of between about 5 percent and about 12 percent of said coenzyme Q-10 or analog thereof that is administered. The ranges of absorbed coenzyme Q-10 are from about 5 percent to about 12 percent, from about 6 percent to about 10 percent, and from about 6.5 percent to about 9.5 percent, based on the dosage of coenzyme Q-10 or analog thereof taken.
In another aspect, the present invention provides solubilized coenzyme Q-10 compositions that include coenzyme Q-10 or an analog thereof, a sufficient quantity of a monoterpene suitable to solubilize said coenzyme Q-10 or analog thereof, and an acceptable carrier. The compositions provide a bioavailable steady state plasma level of coenzyme Q-10 or an analog thereof of between about 2.5 μg/ml to about 3.5 μg/ml. Suitable ranges of steady state plasma levels of coenzyme Q-10 or analog thereof are from about 2.5 μg/ml to about 3.5 μg/ml, from about 2.75 μg/ml to about 3.25 μg/ml and from about 2.75 μg/ml to about 3.0 μg/ml, based on the dosage of coenzyme Q-10 or analog thereof taken.
In still yet another aspect, the present invention provides compositions that include solubilized coenzyme Q-10 or an analog thereof, a sufficient quantity of a monoterpene suitable to solubilize said coenzyme Q-10 or analog thereof, and an acceptable carrier. The compositions provide a peak plasma level of coenzyme Q-10 or analog thereof of between about 2.1 μg/ml to about 3.0 μg/ml. Suitable ranges of peak plasma levels of coenzyme Q-10 or analog thereof are from about 2.1 μg/ml to about 3.0 μg/ml, from about 2.2 μg/ml to about 2.8 μg/ml and from about 2.2 μg/ml to about 2.5 μg/ml.
In another aspect, the present invention pertains to methods for delivery of an effective amount of bioavailable CoQ-10 to an individual. The methods include providing CoQ-10 solubilized in a monoterpene, such that an effective amount of CoQ-10 is provided to the individual so that the dosage absorbed, the steady state plasma levels of coenzyme Q-10, or the peak plasma levels of coenzyme Q-10 are sustained.
In still another embodiment, the present invention also includes packaged formulations of the invention that include a monoterpene as a solvent for the CoQ-10 and instructions for use of the tablet, capsule, elixir, etc. so that the dosage absorbed, the steady state plasma levels of coenzyme Q-10, or the peak plasma levels of coenzyme Q-10 are sustained.
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 FIGURES
FIG. 1 depicts individual single dose (60 mg) peak absorption curves for solubilized coenzyme Q-10;
FIG. 2 shows individual daily dose (60 mg/day) steady state plasma coenzyme Q-10 bioavailability curves for the solubilized coenzyme Q-10;
FIG. 3 provides a graphical representation of single dose peak absorption curves for the solubilized coenzyme Q-10 (60 mg) (upper line, ♦)(Example 5) formulation and Example 6 (30 mg) (lower line, ▪). The Cmax for both formulations occurred at 6 hours. The change in plasma coenzyme Q-10 at Cmax was significantly greater for the solubilized coenzyme Q-10 by a three fold factor. The calculated percentage of dose absorbed at Cmax was 7.95 percent for the solubilized coenzyme Q-10 as compared to 6.04 percent for Example 6; and
FIG. 4 is a graphical representation of the steady state bioavailability curves for the solubilized coenzyme Q-10 (upper line, ♦)(Example 5) and Example 6 (lower line, ▪) at a daily dose of 60 mg/day. Plasma levels at 7, 14, 21 and 28 days were significant (P<0.01) for the solubilized coenzyme Q-10 formulation.
DETAILED DESCRIPTION
The present invention pertains to the surprising discovery that ubiquinone (CoQ-10) can be readily dissolved in varying concentrations in monoterpenes. CoQ-10 is found in most living organisms, and is essential for the production of cellular energy. Ubiquinone is a naturally occurring hydrogen carrier in the respiratory chain (coenzyme Q) and structurally, it is a 2,3-dimethoxy-5-methyl-1,4-benzoquinone with a multiprenyl side chain, the number of isoprene units varying depending upon the organism from which it is derived. CoQ-10 analogs include reduced and semi-reduced CoQ-10 and ubiquinone derivatives described, for example, in WO 8803015, the teachings of which are incorporated herein by reference.
Generally, until the present discovery, most CoQ-10 liquid delivery methods could solubilize only up at most about 10% by weight of the CoQ-10 in the solvent. Typical solvents included oils or the CoQ-10 was held in an aqueous suspension. Alternatively, the CoQ-10 was provided as a solid in a tablet or powder.
The present invention provides the ability to solubilize CoQ-10 and analogs thereof in monoterpenes, as defined herein, in concentrations of up to about 60% (weight to weight) without the need to heat the solution. In one aspect, the monoterpene solubilizes CoQ-10 from about 0.1 percent by weight to about 45 percent by weight.
In particular, the solubilization of the CoQ-10 and analogs thereof with monoterpenes can be accomplished at ambient temperatures. In one aspect, from about 5 to about 50 percent (weight CoQ-10 weight solvent) CoQ-10 can be solubilized in a monoterpene. In another aspect, from about 15 to about 40 percent w/w can be solubilized and in still another aspect, from about 20 to about 35 percent w/w CoQ-10 can be solubilized in a monoterpene.
The phrase “sufficient quantity of a monoterpene suitable to solubilize coenzyme Q-10” is therefore intended to mean that that amount of a monoterpene that will dissolve CoQ-10 under a given set of conditions, generally, those at ambient temperature. This determination should be understood by one skilled in the art and can be determined by methods known in the art, such as by solubility studies.
One of the particular advantages of utilizing monoterpenes in combination with CoQ-10 and analogs thereof is that the enzyme is dissolved by the monoterpene. That is, many formulations currently in the marketplace have CoQ-10 present as a suspension; a situation where not all the CoQ-10 is dissolved. This reduces efficacy and the bioavailability of the CoQ-10. The present invention eliminates this disadvantage by solubilizing the CoQ-10 in the monoterpene.
A particular advantage in using monoterpenes is that the CoQ-10 or analog thereof does not have to be heated to dissolve into solution. This is important so that the CoQ-10 or analog thereof does not degrade upon dissolution.
The term “monoterpene” as used herein, refers to a compound having a 10-carbon skeleton with non-linear branches. A monoterpene refers to a compound with two isoprene units connected in a head-to-end manner. The term “monoterpene” is also intended to include “monoterpenoid”, which refers to a monoterpene-like substance and may be used loosely herein to refer collectively to monoterpenoid derivatives as well as monoterpenoid analogs. Monoterpenoids can therefore include monoterpenes, alcohols, ketones, aldehydes, ethers, acids, hydrocarbons without an oxygen functional group, and so forth.
It is common practice to refer to certain phenolic compounds, such as eugenol, thymol and carvacrol, as monoterpenoids because their function is essentially the same as a monoterpenoid. However, these compounds are not technically “monoterpenoids” (or “monoterpenes”) because they are not synthesized by the same isoprene biosynthesis pathway, but rather by production of phenols from tyrosine. However, common practice will be followed herein. Suitable examples of monoterpenes include, but are not limited to, limonene, pinene, cintronellol, terpinene, nerol, menthane, carveol, S-linalool, safrol, cinnamic acid, apiol, geraniol, thymol, citral, carvone, camphor, etc. and derivatives thereof. For information about the structure and synthesis of terpenes, including terpenes of the invention, see Kirk-Othmer Encyclopedia of Chemical Technology, Mark, et al., eds., 22:709-762 3d Ed (1983), the teachings of which are incorporated herein in their entirety.
In particular, suitable limonene derivatives include perillyl alcohol, perillic acid, cis-dihydroperillic acid, trans-dihydroperillic acid, methyl esters of perillic acid, methyl esters of dihydroperillic acid, limonene-2-diol, uroterpenol, and combinations thereof.
Formulation of the CoQ-10 and analogs thereof can be accomplished by many methods known in the art. For example, the solubilized CoQ-10 or analog thereof can be formulated in a suspension, an emulsion, an elixir, a solution, a caplet that harbors the liquid, or in a soft gelatin capsule. Often the formulation will include an acceptable carrier, such as an oil, or other suspending agent.
Suitable carriers include but are not limited to, for example, fatty acids, esters and salts thereof, that can be derived from any source, including, without limitation, natural or synthetic oils, fats, waxes or combinations thereof. Moreover, the fatty acids can be derived, without limitation, from non-hydrogenated oils, partially hydrogenated oils, fully hydrogenated oils or combinations thereof. Non-limiting exemplary sources of fatty acids (their esters and salts) include seed oil, fish or marine oil, canola oil, vegetable oil, safflower oil, sunflower oil, nasturtium seed oil, mustard seed oil, olive oil, sesame oil, soybean oil, corn oil, peanut oil, cottonseed oil, rice bran oil, babassu nut oil, palm oil, low erucic rapeseed oil, palm kernel oil, lupin oil, coconut oil, flaxseed oil, evening primrose oil, jojoba, tallow, beef tallow, butter, chicken fat, lard, dairy butterfat, shea butter or combinations thereof.
Specific non-limiting exemplary fish or marine oil sources include shellfish oil, tuna oil, mackerel oil, salmon oil, menhaden, anchovy, herring, trout, sardines or combinations thereof. In particular, the source of the fatty acids is fish or marine oil (DHA or EPA), soybean oil or flaxseed oil. Alternatively or in combination with one of the above identified carrier, beeswax can be used as a suitable carrier, as well as suspending agents such as silica (silicon dioxide).
The formulations of the invention are considered dietary supplements useful to the increase the amounts of CoQ-10 and analogs thereof in the individuals in need thereof.
Alternatively, the formulations of the invention are also considered to be nutraceuticals. The term “nutraceutical” is recognized in the art and is intended to describe specific chemical compounds found in foods that may prevent disease. CoQ-10 or an analog thereof are such compounds.
The formulations of the invention can further include various ingredients to help stabilize, or help promote the bioavailability of the CoQ-10 and analogs thereof, or serve as additional nutrients to an individual's diet. Suitable additives can include vitamins and biologically-acceptable minerals. Non-limiting examples of vitamins include vitamin A, B vitamins, vitamin C, vitamin D, vitamin E, vitamin K and folic acid. Non-limiting examples of minerals include iron, calcium, magnesium, potassium, copper, chromium, zinc, molybdenum, iodine, boron, selenium, manganese, derivatives thereof or combinations thereof. These vitamins and minerals may be from any source or combination of sources, without limitation. Non-limiting exemplary B vitamins include, without limitation, thiamine, niacinamide, pyridoxine, riboflavin, cyanocobalamin, biotin, pantothenic acid or combinations thereof.
Vitamin(s), if present, are present in the composition of the invention in an amount ranging from about 5 mg to about 500 mg. More particularly, the vitamin(s) is present in an amount ranging from about 10 mg to about 400 mg. Even more specifically, the vitamin(s) is present from about 250 mg to about 400 mg. Most specifically, the vitamin(s) is present in an amount ranging from about 10 mg to about 50 mg. For example, B vitamins are in usually incorporated in the range of about 1 milligram to about 10 milligrams, i.e., from about 3 micrograms to about 50 micrograms of B12. Folic acid, for example, is generally incorporated in a range of about 50 to about 400 micrograms, biotin is generally incorporated in a range of about 25 to about 700 micrograms and cyanocobalamin is incorporated in a range of about 3 micrograms to about 50 micrograms.
Mineral(s), if present, are present in the composition of the invention in an amount ranging from about 25 mg to about 1000 mg. More particularly, the mineral(s) are present in the composition ranging from about 25 mg to about 500 mg. Even more particularly, the mineral(s) are present in the composition in an amount ranging from about 100 mg to about 600 mg.
Various additives can be incorporated into the present compositions. Optional additives of the present composition include, without limitation, phospholipids, L-carnitine, starches, sugars, fats, antioxidants, amino acids, proteins, flavorings, coloring agents, hydrolyzed starch(es) and derivatives thereof or combinations thereof.
As used herein, the term “phospholipid” is recognized in the art, and refers to phosphatidyl glycerol, phosphatidyl inositol, phosphatidyl serine, phosphatidyl choline, phosphatidyl ethanolamine, as well as phosphatidic acids, ceramides, cerebrosides, sphingomyelins and cardiolipins.
L-carnitine is recognized in the art and facilitates transport of materials through the mitochondrial membrane. L-carnitine is an essential fatty acid metabolism cofactor that helps to move fatty acids to the mitochondria from the cytoplasm. This is an important factor as this is where CoQ-10 uptake occurs.
In one aspect of the present invention, L-carnitine is included in soft gel formulations in combination with CoQ-10 or an analog thereof. Suitable ratios of L-carnitine and CoQ-10 are known in the art and include those described in U.S. Pat. No. 4,599,232, issued to Sigma Tau Industrie Faramaceutiche Riunite S.p.A. on Jul. 8, 1986, the teachings of which are incorporated herein in their entirety. In particular, combinations of limonene, CoQ-10 and L-carnitine in soft gel formulations are of importance. The present invention provides the advantage of solvating large amounts (relative to that of current state of the art) of CoQ-10 in limonene in a soft gel capsule along with an additive, such as L-carnitine.
As used herein, the term “antioxidant” is recognized in the art and refers to synthetic or natural substances that prevent or delay the oxidative deterioration of a compound. Exemplary antioxidants include tocopherols, flavonoids, catechins, superoxide dismutase, lecithin, gamma oryzanol; vitamins, such as vitamins A, C (ascorbic acid) and E and beta-carotene; natural components such as camosol, carnosic acid and rosmanol found in rosemary and hawthorn extract, proanthocyanidins such as those found in grapeseed or pine bark extract, and green tea extract.
The term “flavonoid” as used herein is recognized in the art and is intended to include those plant pigments found in many foods that are thought to help protect the body from cancer. These include, for example, epi-gallo catechin gallate (EGCG), epi-gallo catechin (EGC) and epi-catechin (EC).
The phrase “solubilized CoQ-10 and analogs thereof” is intended to mean that the coenzyme Q-10 is solvated by the lipophilic materials incorporated into the soft gel capsule. Typical capsules that contain CoQ-10 or an analog thereof include the coenzyme or analog as a dry powder or as a suspension of crystals. It is believed that the powder or crystallinity of the coenzyme does not facilitate absorption by the cells. The present invention overcomes this disadvantage by providing formulations wherein the coenzyme is not in a powdered or crystalline form. Microscopic evaluations of the lipophilic formulations do not show crystals of the coenzyme. Consequently, it is believed that the solvated coenzyme can more easily pass into cells. This is highly advantageous in delivering increased amounts of the coenzyme into an individual's physiological make up.
Any dosage form, and combinations thereof, are contemplated by the present invention. Examples of such dosage forms include, without limitation, chewable tablets, elixirs, liquids, solutions, suspensions, emulsions, capsules, soft gelatin capsules, hard gelatin capsules, caplets, lozenges, chewable lozenges, suppositories, creams, topicals, ingestibles, injectables, infusions, health bars, confections, animal feeds, cereals, cereal coatings, and combinations thereof. The preparation of the above dosage forms are well known to persons of ordinary skill in the art.
For example, health bars can be prepared, without limitation, by mixing the formulation plus excipients (e.g., binders, fillers, flavors, colors, etc.) to a plastic mass consistency. The mass is then either extended or molded to form “candy bar” shapes that are then dried or allowed to solidify to form the final product.
Soft gel or soft gelatin capsules can be prepared, for example, without limitation, by dispersing the formulation in an appropriate vehicle (e.g. rice bran oil, monoterpene and/or beeswax) to form a high viscosity mixture. This mixture is then encapsulated with a gelatin based film using technology and machinery known to those in the soft gel industry. The industrial units so formed are then dried to constant weight. Typically, the weight of the capsule is between about 100 to about 2500 milligrams and in particular weigh between about 1500 and about 1900 milligrams, and more specifically can weigh between about 1500 and about 2000 milligrams.
For example, when preparing soft gelatin shells, the shell can include between about 20 to 70 percent gelatin, generally a plasticizer and about 5 to about 60% by weight sorbitol. The filling of the soft gelatin capsule is liquid (principally limonene, in combination with rice bran oil and/or beeswax if desired) and can include, apart form the antioxidant actives, a hydrophilic matrix. The hydrophilic matrix, if present, is a polyethylene glycol having an average molecular weight of from about 200 to 1000. Further ingredients are optionally thickening agents. In one embodiment, the hydrophilic matrix includes polyethylene glycol having an average molecular weight of from about 200 to 1000, 5 to 15% glycerol, and 5 to 15% by weight of water. The polyethylene glycol can also be mixed with propylene glycol and/or propylene carbonate.
In another embodiment, the soft gel capsule is prepared from gelatin, glycerine, water and various additives. Typically, the percentage (by weight) of the gelatin is between about 30 and about 50 weight percent, in particular between about 35 and about weight percent and more specifically about 42 weight percent. The formulation includes between about 15 and about 25 weight percent glycerine, more particularly between about 17 and about 23 weight percent and more specifically about 20 weight percent glycerine.
The remaining portion of the capsule is typically water. The amount varies from between about 25 weigh percent and about 40 weight percent, more particularly between about 30 and about 35 weight percent, and more specifically about 35 weight percent. The remainder of the capsule can vary, generally, between about 2 and about 10 weight percent composed of a flavoring agent(s), sugar, coloring agent(s), etc. or combination thereof. After the capsule is processed, the water content of the final capsule is often between about 5 and about 10 weight percent, more particularly 7 and about 12 weight percent, and more specifically between about 9 and about 10 weight percent.
As for the manufacturing, it is contemplated that standard soft shell gelatin capsule manufacturing techniques can be used to prepare the soft-shell product. Examples of useful manufacturing techniques are the plate process, the rotary die process pioneered by R. P. Scherer, the process using the Norton capsule machine, and the Accogel machine and process developed by Lederle. Each of these processes are mature technologies and are all widely available to any one wishing to prepare soft gelatin capsules.
Typically, when a soft gel capsule is prepared, the total weight is between about 250 milligrams and about 2.5 gram in weight, e.g., 400-750 milligrams. Therefore, the total weight of additives, such as vitamins and antioxidants, is between about 80 milligrams and about 2000 milligrams, alternatively, between about 100 milligrams and about 1500 milligrams, and in particular between about 120 milligrams and about 1200 milligrams.
For example, a soft gel capsule can be prepared by mixing a 35% solution of CoQ-10 and limonene (w/w) (e.g., 104 milligrams of CoQ-10 in 193.14 milligrams of limonene) with between about 0.01 grams and about 0.4 grams (e.g., 0.1 grams) tocopherol, between about 200 grams and about 250 grams (e.g., 225 grams) rice bran oil and between about 0.01 grams and about 0.5 grams betacarotene (e.g. about 0.02 grams). The mixture is then combined with encapsulated within a gelatin capsule as described above.
The present invention also provides packaged formulations of a monoterpene with CoQ-10 and instructions for use of the tablet, capsule, elixir, etc. Typically, the packaged formulation, in whatever form, is administered to an individual in need thereof that requires and increase in the amount of CoQ-10 in the individual's diet. Typically, the dosage requirements is between about 1 to about 4 dosages a day.
CoQ-10 has been implicated in various biochemical pathways and is suitable for the treatment of cardiovascular conditions, such as those associated with, for example, statin drugs that effect the body's ability to produce CoQ-10 naturally. CoQ-10 has also been implicated in various periodontal diseases. Furthermore, CoQ-10 has been implicated in mitochondrial related diseases and disorders, such as the inability to product acetyl coenzyme A, neurological disorders, for example, such as Parkinson's disease and, Prater-Willey syndrome.
The following examples are intended to be illustrative only and should not be considered limiting.
EXAMPLES
Formulations of CoQ-10 can be prepared in the following ratios by mixing the components together and then placing into a soft gel capsule.
Component
Example 1
Example 2
CoQ-10
104.09 mg
104.09 mg
Mixed Tocopherols
269.03 mg
269.03 mg
(372 IU/g)
Rice Bran Oil
176.02 mg
—
Natural Beta Carotene
10.05 mg
10.05 mg
(20% by weight)
Yellow Beeswax
20.0 mg
—
D-limonene
—
196.02 mg
Total weight
580 mg
580 mg
Example 2 demonstrates that the use of limonene solubilizes CoQ-10 without the requirement of beeswax and/or rice bran oil being present. Examples 1 and 2 can be incorporated into soft gel capsules by standard methods known in the art.
Component
Example 3
Example 4
CoQ-10
17.95 g
17.95 g
EPAX 2050TG
48.77 g
45.49 g
D-Limonene
35.70 g
35.70 g
5-67 Tocopherol
—
0.86 g
(1000 IU/g)
Examples 3 and 4 demonstrate that CoQ-10 can be solubilized in scalable quantities. Additives, such as EPAX 2050 TG (an ω-3 oil; 20% EPA/50% DHA as triglycerides, remainder fatty acid/triglycerides; Pronova Biocare) and tocopherols (5-67 Tocopherol; BD Industries) can easily be incorporated into such limonene containing formulations. The resultant mixtures contained approximately 100 mg of CoQ-10 per soft gel capsule. Preparation of the soft gel capsules was accomplished by methods well known in the art.
Component
Example 5
Example 6
CoQ-10 (98%)
62.45 mg
62.45 mg
Vitamin E mixed tocopherols
69.19 mg
161.3. mg
(700 mg/g)
D-Limonene
118.1 mg
none
Soybean oil
30.26 mg
none
5-67 Tocopherol
60.0 mg
none
(1000 IU/g)
yellow beeswax
none
15.0 mg
Rice bran oil
none
188.71 mg
Natural beta Carotene
none
7.54 mg
mg/capsule
mg/capsule
Examples 5 and 6 provide a comparison between soft gel capsules prepared with D-limonene and without D-limonene and enzyme CoQ-10. Examples 5 and 6 will be referred to throughout the following paragraphs to show efficacy in delivery with the use of the monoterpene, D-limonene.
The single 60 mg dose peak absorption characteristics and the 28-day 60 mg daily dose steady state bioavailability of the solubilized CoQ 10 formulation was determined in five (5) normal male (N=3) and female (N=2) volunteers. The peak absorption study was done over 12 hours. For the control sample, the volunteers were in a rested and fasted condition-minimum eight (8) hours. Serial blood samples were taken at 0, 4, 6, 8, and 12 hours after ingesting 60 mg of a softgel product (either solubilized CoQ 10 (Example 5) or Example 6, a non-solubilized CoQ 10 formulation. In the steady state bioavailability study, daily doses of 60 mg of the solubilized CoQ 10 formulation were taken with breakfast. CoQ 10 in plasma was measured using the hexane extraction and HPLC detection method described in “A New Method to Determine the Level of Coenzyme Q10 in One Drop of Human Blood for Biomedical Research”, Manabu Morita and Karl Folkers, Biochem. Biophys. Res. Commun. 191(3), 950-954,1993, the contents of which are incorporated herein in their entirety. The solubilized CoQ 10 formulation was a soft gel capsule that contained 60 mg CoQ 10 , 118.1 mg limonene, 30.26 mg soybean oil and vitamin E as described in Example 5. The non-solubilized formulation was a soft gel capsule that contained 60 mg CoQ 10 , 188.71 mg rice bran oil, 161.3 mg vitamin E (and additional additives) as described in Example 6.
Group mean control plasma CoQ 10 level (0.88±0.13 μg/ml) was in the normal range. Tmax after ingestion of a single 60 mg capsule was in six (6) hours and the mean peak plasma level (Cmax) was 2.28±0.14 μg/ml. The amount of solubilized CoQ 10 absorbed at Cmax was 4,765.51±825.39 μg or 7.96±1.38% of the ingested dose. With daily dosing the plasma solubilized CoQ 10 level increased to a mean plateau level of 2.68±0.15 μg/ml in 14 days and remained fairly constant thereafter. The 28-day plasma level was 2.75±0.22 μg/ml. The solubilized CoQ 10 bioavailability in plasma was 6,498.90±1,634.76 μg, and the area under the plasma time base curve was 42.27±2.29 μg/ml·day. These data demonstrate that the solubilized CoQ 10 formulation was absorbed significantly (p<0.001). The peak absorption of 7.96% ofthe ingested dose and the steady state bioavailability after 28 days was significantly (p<0.01) greater than that found in Example 6.
The solubilized CoQ 10 formulation (Example 5) absorption is greater than that of most softgel CoQ 10 products in which CoQ 10 crystals are suspended in a lipid base and those products that provide only a dried powder composition.
Peak Absorption Characteristics and Steady State Bioavailability of Solubilized CoQ 10 Formulation
The use of Coenzyme Q 10 (CoQ 10 ) around the world has surpassed the production capabilities of the Japanese producers. CoQ 10 is also rapidly entering the clinical consumer market with the positive study reports on heart failure, Parkinson's disease, muscular ataxias, low energy genetic syndromes, statin drug inhibition of CoQ 10 synthesis and recent publications that show that CoQ 10 and its precursors in the body inhibit farensyl-transferase and thus turn off the growth and rapid division of cancer cells. With these advances in CoQ 10 research and the conclusions that plasma CoQ 10 levels for clinical efficacy should be raised to about 3.2 μg/ml, more companies have been seeking to develop CoQ 10 products with improved absorption and steady state bioavailability. The absorption of CoQ 10 is not the same for all CoQ 10 products found in the market place. In general dry powder delivery systems have 0.5 to 2% peak absorption. Dry powder CoQ 10 in a lipid base that is incorporated into soft gelatin capsules has better peak absorption (2.0-3.0%). This appears to be dependant on the number and size of the CoQ 10 crystals in the product.
The following data relate to peak absorption characteristics of a single 60 mg dose and the steady state bioavailability of a daily 60 mg dose for the solubilized CoQ 10 softgel formulation. Both studies were conducted on the same five (5) normal volunteer subjects. Peak absorption and steady state bioavailability characteristics were compared to that of Example 6 which was collected using a similar study design but different volunteers.
Methods
Five normal volunteers (3 males/2 females) were randomly selected from a screened group of 15 individuals (Table I). The exclusion criteria were: 1) smoker, 2) individual taking a CoQ 10 product, 3) individual with high plasma cholesterol, 4) individual taking drugs known to interfere with endogenous synthesis or CoQ 10 absorption, 5) individual on vegetarian diet, and 6) athlete.
TABLE I
Physical Characteristics of Study Volunteers
PLASMA
AGE
HEIGHT
WEIGHT
VOLUME
VOLUNTEER
YEARS
SEX
INCHES
POUNDS
MILLILITERS
PDOB 01
43
F
63.50
147.00
3139.00
RFRE 02
42
M
66.25
170.75
3720.00
AJOH 03
43
M
69.50
205.00
3928.00
SHAL 04
26
M
70.50
192.50
3870.00
NJOH 05
39
F
63.75
126.00
2520.00
After being fully familiarized with the experimental design and their responsibilities, the volunteers had their questions answered by the principle investigator, and read and signed a volunteer consent form. On day 0 of the study, volunteers reported to the testing facility at 0600 in a rested and fasted state-minimum eight (8) hours. Vital signs were taken, an intercath was placed in a forearm vein, and a control blood sample was collected for determining the control CoQ 10 plasma level. The volunteers were then given a single 60 mg dose of the solubilized CoQ 10 formulation. This was followed by a breakfast consisting of orange juice or milk (2%) with a bagel or cereal. Blood samples were drawn again at hours 4, 6, 8 and 12; vital signs and safety data were collected simultaneously. Starting with day 1 of the study, the volunteers took 60 mg of solubilized CoQ 10 formulation daily for the next 28 days. During this time, volunteers followed their regular diet and activity schedules and returned to the testing facility on days 7, 14, 21, and 28 at 0600 in a rested and fasted condition-minimum eight (8) hours—for the purpose of collecting vital signs and safety data, and to have a venous blood sample collected from which plasma CoQ 10 levels were determined.
All CoQ 10 samples were collected in vaccutainers containing EDTA to prevent clotting. The samples were cooled in ice water and then centrifuged to separate the plasma from the formed elements. The plasma was pipetted into a sealable transfer container, labeled according to volunteer identification and hour of collection and frozen at −20° centigrade. All plasma samples were shipped overnight in dry ice to an independent laboratory for CoQ 10 analysis. The method used was that as described in Morita & Folkers (supra) hexane extraction and HPLC detection.
Individual volunteer data points were entered into a Microsoft Excel spreadsheet. Descriptive statistics were used to calculate group means SD and SE. Statistical differences between group control and each group sample for the peak absorption and the steady state weekly levels were determined using a standard t-test for differences between group means. A probability of p≦0.05 was accepted as significant.
Results
I: Peak Absorption Study
Individual and group means ±SE & SD descriptive statistics data for the 60 mg single dose peak absorption study are presented in Table II and the individual data plotted on a 12 hour time base are shown in FIG. 1 . Control plasma CoQ 10 was variable between volunteers (range=0.77-1.09 μg/ml). The group means ±SD was 0.88±0.13 μg/ml. This is considered to be in the normal range. Within four hours after ingesting the solubilized CoQ 10 the plasma levels for the group increased significantly (p<0.01) to 1.36±0.12 μg/ml. Peak plasma levels occurred at six (6) hours (Tmax) and the maximum plasma concentration (Cmax) was 2.28±0.14 μg/ml. T hereafter plasma CoQ 10 rapidly decreased over the next two hours to a mean level of 1.58±0.23 μg/ml during the rapid tissue uptake period of CoQ 10 . The peak absorption kinetics calculated from the peak absorption data are presented in Table IV.
TABLE II
Individual and Group Solubilized CoQ 10 formulation:
Single Dose (60 mg) Peak Absorption Study
Sample Time (Hours)
Volunteer
0
4
6
8
12
1
0.77
1.35
2.09
1.30
1.10
2
1.09
1.56
2.40
1.60
1.46
3
0.92
1.36
2.39
1.90
1.76
4
0.79
1.24
2.16
1.42
1.27
5
0.85
1.28
2.34
1.67
1.45
Mean
0.88
1.36
2.28
1.58
1.41
Standard Error
0.06
0.06
0.06
0.10
0.11
Standard
0.13
0.12
0.14
0.23
0.25
Deviation
P-value
3.24E−05
1.57E−06
0.000766
0.002338
The amount of CoQ 10 absorbed at Cmax was 4,769.51±825.39 μg. When compared to the ingested dose (60,000 μg), the percent of the dose absorbed at Cmax was 7.95±1.38%. In the first two hours after Cmax an average of 2196.14±523.83 μg was distributed out of the blood and into the body cells. The amount was 46.46±9.85% of that absorbed at Cmax.
II: Steady State Plasma CoQ 10 Bioavailability
Individual and group means ±SD descriptive statistics data for the 28-day 60mg/day steady state plasma CoQ 10 bioavailability for the solubilized CoQ 10 formulation are presented in Table III and graphically in FIGS. 2 and 4 . Again there was a variation between volunteers. In seven (7) days the basal plasma CoQ 10 level increased significantly (p<0.01) to 2.39±0.13 μg/ml. Plasma levels plateaued for each volunteer between the 7th and 14th day and remained fairly constant thereafter ( FIG. 2 ). At the 28th day the group means plasma CoQ 10 level was 2.75±0.22 μg/ml (p<0.001). The calculated steady state increase in plasma CoQ 10 was 6,458.90±1,634.76 μg at a constant daily dose of 60mg/day (Table V). In a steady state condition the group mean relative increase in plasma CoQ 10 was 314.42±39.07%. The area under the plasma CoQ 10 and time base curve between days 0 and 28 days (AUC 0-28day )(AUC denotes area under the curve) is used to equate the CoQ 10 bioavailability. The AUC for this product was 42.27±2.29 μg/ml·day.
TABLE III
Individual and Group Solubilized CoQ 10 : Steady State (60 mg/day)
Plasma CoQ10 Bioavailability Study
Time (Days)
AUC (0-28 day)
Volunteer
0
7
14
21
28
% Change
ug/ml · day
1
0.77
2.20
2.48
2.56
2.67
285.71
42.77
2
1.09
2.30
2.79
2.80
2.78
211.01
38.68
3
0.92
2.52
2.78
3.00
3.10
273.91
42.22
4
0.79
2.42
2.78
2.70
2.68
306.33
42.61
5
0.85
2.49
2.56
2.60
2.50
292.94
45.05
Mean
0.88
2.39
2.68
2.73
2.75
314.42
42.27
Standard Error
0.06
0.06
0.07
0.08
0.10
17.47
1.02
Standard Deviation
0.13
0.13
0.15
0.18
0.22
39.07
2.29
p-value
2.65E−05
3.11E−06
5.13E−06
5.13E−06
TABLE IV
Individual and Group Single Dose Peak Absorption Characteristics for Solubilized CoQ 10 formulation
Control
Change
Plasma
Plasma
Plasma
Change in
Rapid Q10
Amt. Q10
% Distributed
Q10
Cmax
Q10
Plasma
Plasma
% of Dose
Distribution
Distributed
of Amt.
Volunteer
ug/ml
ug/ml
ug/ml
Vol ml
Q10 ug
Absorbed
ug/ml
ug
Absorbed
1
0.77
2.09
1.32
3139.00
4143.48
6.91
0.61
1914.79
46.21
2
1.09
2.40
1.31
3720.00
4873.20
8.12
0.80
2976.00
61.07
3
0.92
2.39
1.47
3928.00
5774.16
9.62
0.49
1924.72
33.33
4
0.79
2.16
1.37
3870.00
5301.90
8.84
0.64
2476.80
46.72
5
0.85
2.34
1.49
2520.00
3754.80
6.26
0.67
1688.40
44.97
Mean
0.88
2.28
1.48
3435.40
4769.51
7.95
0.64
2196.14
46.46
SD
0.06
0.06
0.08
268.17
369.12
0.62
0.05
234.26
4.41
SE
0.13
0.14
1.39
599.65
825.39
1.38
0.11
523.83
9.85
III: Particle and Crystalline Characteristics of Solubilized CoQ 10
Photomicrographs of solubilized CoQ 10 (Example 5) and Example 6 showed that Example 6 had many small crystals of CoQ 10 , whereas the solubilized CoQ 10 (Example 5) showed no crystals, and appeared to be a homogenous distribution of CoQ 10 molecules in solution.
Discussion
The study determined the peak single dose (60 mg) absorption characteristics and the steady state plasma CoQ 10 bioavailability in response to a constant daily dose of 60 mg/day for 28 days of solubilized CoQ 10 . The control plasma CoQ 10 data for the small group (N=5) was in the normal range (Tables 1 & 2). The plasma CoQ 10 increase at Cmax (2.28±0.14 μg/ml) was significantly (p<0.001) above the control level as was the amount of CoQ 10 added to the plasma at Cmax (Table IV and V).
TABLE V
Individual and Group Solubilized CoQ 10 (Example 5): Steady State
(60 mg/day) CoQ 10 Bioavailability Study
Plasma Q
C-CoQ10
28 Day
Change
Plasma Vol
Change
AUC (0-28 day)
Volunteer
ug/ml
ug/ml
ug/ml
ml
ug/ml
% Change
ug/ml · day
1
0.77
2.67
1.90
3,139.00
5,964.10
346.75
42.77
2
1.09
2.78
1.69
3,720.00
6,286.80
255.05
38.68
3
0.92
3.10
2.18
3,928.00
8,563.04
336.96
42.22
4
0.79
2.68
1.89
3,870.00
7,314.30
339.24
42.61
5
0.85
2.50
1.65
2,525.00
4,166.25
294.12
45.05
Mean
0.88
2.75
1.86
3,436.40
6,458.90
314.42
42.27
Standard
0.06
0.10
0.09
267.32
731.09
17.47
1.02
Error
Standard
0.13
0.22
0.21
597.75
1,634.76
39.07
2.29
Deviation
Peak absorption and steady state bioavailability data were compared between the solubilized CoQ 10 (Example 5) and Example 6. Comparisons were made by examining FIGS. 3 and 4 . These Figures show the peak absorption curves ( FIG. 3 ) and the steady state bioavailability curves ( FIG. 4 ) characteristics of both the solubilized CoQ 10 and CoQ 10sol products plotted on the same time base. Cmax for Example 6 with a 30 mg dose increased 0.53±0.28 μg/ml above the control level. With this change in plasma CoQ 10 1813.33±96.65 μg of CoQ 10 was added to the blood at Cmax. The calculated percent (%) of ingested dose absorbed was 6.04±0.32%. This is significantly less than the 1.48±0.39 ug/ml change in plasma CoQ 10 and the 7.95±1.38% of the 60 mg ingested dose of the solubilized CoQ 10 formulation. Thus, the relative increases in the peak plasma CoQ 10 at Cmax, the amount of CoQ 10 absorbed at Cmax and the percent of ingested dose absorbed at Cmax between the solubilized CoQ 10 (Example 5) and Example 6 formulations were 80, 60 and 40 percent greater respectively for the solubilized CoQ 10 formulation. These data show that Example 6 at a dose of 30 mg is significantly (p<0.01) less absorbed than 60 mg of solubilized CoQ 10 formulation. The steady state bioavailability of Example 6 is also significantly less than that of solubilized CoQ 10 formulation as shown in FIG. 4 .
At 28 days with a 60 mg daily dose, Example 6 resulted in a group mean steady state plasma CoQ 10 level of 2.26±0.74 μg/ml. This is significantly (p<0.01) less than the 2.75±0.22 μg/ml measured for the solubilized CoQ 10 formulation using the same 60 mg/day dose. Similarly, the AUCo-28 day for the solubilized CoQ 10 , CoQ 10 was significantly greater (p≦0.01) than that found for Example 6 (42.27±2.29—vs.—29.6±4.61 μg/ml/day). These data comparisons also show that the solubilized CoQ 10 formulation CoQ 10 bioavailability is significantly greater than that of Example 6.
Not to be limited by theory, as to why the solubilized CoQ 10 formulation (Example 5) has better absorption than Example 6 may be explained by the physical characteristics of the two formulations. Both Example 6 and the solubilized CoQ 10 formulations were made by the same soft gel encapsulating process. The ingredients in the two formulations were different relative to the lipid carrier molecules (Rice bran oil in Example 6 and Soybean oil and D-Limonene oil in the solubilized CoQ 10 formulation (Example 5)). On examination of the two formulations, the contents of both were an oily matrix. The solubilized CoQ 10 formulation appeared to be more liquid (less solids) than Example 6. Example 6 was reddish brown in color due to the beta-carotene. The solubilized CoQ 10 formulation was dark brown in color. Upon microscopic examination Example 6 was found to have small crystals, whereas the solubilized CoQ 10 was devoid of crystals. It is postulated that the solubilized CoQ 10 formulation consists of a larger fraction of single CoQ 10 molecules and exerts a greater osmotic concentration of CoQ 10 outside the intestinal cells, thus a greater driving force for the facilitated diffusion process for CoQ 10 absorption.
Since the CoQ 10 crystal has a melting point 10° centigrade above body temperature (37° C.) and completely melt to single molecules at 65° centigrade, it is believed that the lower absorption of Example 6 is due to the larger proportion of CoQ 10 crystals in solution and the physiological fact that the body cannot absorb a crystal. Only single molecules in water or lipid solution can be absorbed across the intestinal mucosal membrane or transported across any epithelial cell membrane.
In summary, the solubilized CoQ 10 formulation peak absorption kinetics and steady state bioavailability is significantly greater than that of Example 6. The 7.95% absorption of the ingested dose makes this a superior composition to provide increased amounts of CoQ 10 to a subject in need thereof.
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.
All literature and patent references cited throughout the application are incorporated by reference into the application for all purposes. | The present invention is directed to compositions and methods of delivery of CoQ-10 solubilized in monoterpenes. Use of monoterpenes as dissolving agents, greatly effects the ability to incorporate greater amounts of bioactive CoQ-10 in formulations, such as soft gel capsules. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an air blower inside an air-cushioned bed, and more particularly to a built-in air blower inside the bed to inflate or deflate the air-cushioned bed.
[0003] 2. Description of Related Art
[0004] A conventional air-cushioned bed has a large air cell with air contained therein. Due to the cushion effect provided by the air in the air cell, the user lying on the air-cushioned bed is able to have excellent support. In order to facilitate the inflation and deflation of the air cell, the air cell is provided with an air nozzle communicating the interior of the air cell with surrounding air. The user is able to use an air compressor or the like to inflate or deflate the air cell via the air nozzle.
[0005] However, it is well known in the art that even if the size of the air compressor is small, it is hard for the user to prepare a storing space for the air compressor. Furthermore, because airbeds tend to used infrequently, such as once or twice in the summer, it is easy for the compressor to become hidden from view by other things stored.
[0006] To overcome the shortcomings, the present invention tends to provide an improved air-cushioned bed to mitigate the aforementioned problems.
SUMMARY OF THE INVENTION
[0007] The primary objective of the present invention is to provide an improved air-cushioned bed with a built-in air blower so that additional space otherwise needed for storing the air blower is saved.
[0008] Another objective of the present invention is that the air blower is detachably received in a container such that either inflation or deflation of the air cell of the air-cushioned bed is easily accomplished.
[0009] Other objects, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a schematic perspective view showing that an air blower is received in an air-cushioned bed of the present invention;
[0011] [0011]FIG. 2 is an exploded perspective view showing the relation between the air blower and a casing;
[0012] [0012]FIG. 3 is a schematic side plan view in partial section to show relationship between the position plate and the air blower inside the casing;
[0013] [0013]FIG. 4 is a schematic side plan view showing that the air blower is securely clamped by the position plate inside the casing;
[0014] [0014]FIG. 5 is a schematic side plan view showing the relationship between the position plate and the casing; and
[0015] [0015]FIG. 6 is a perspective view showing that the air blower is securely positioned inside the casing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] With reference to FIG. 1, the air-cushioned bed ( 10 ) of the present invention includes a concave space ( 11 ) defined in a side face of the air-cushioned bed ( 10 ), a casing ( 20 ) and an air blower ( 30 ) received inside the casing ( 20 ).
[0017] With reference to FIG. 2, it is noted that the air blower ( 30 ) is capable of sucking air from surrounding atmosphere into an inlet ( 31 ) and blowing air out of the air blower ( 30 ) from an outlet ( 32 ). The inlet ( 31 ) has a first annular flange ( 311 ) and the outlet ( 32 ) has a second annular flange ( 321 ). Further the air blower ( 30 ) has a switch ( 33 ) mounted on an outer surface of the air blower ( 30 ) to control activation and deactivation of the air blower ( 30 ). The internal structure of the air blower ( 30 ) is not the subject of the application such that detailed description thereof is omitted.
[0018] The casing ( 20 ) has a U-shaped cross section and includes a body ( 21 ), a through hole ( 22 ) defined in a side face of the body ( 21 ), a cover ( 23 ) pivotally connected to a circumference defining the through hole ( 22 ) to optionally plug the through hole ( 22 ), a sliding seat ( 24 ) formed on an inner side face of the body ( 21 ) and opposite to the through hole ( 22 ), and a position plate ( 25 ) slidable with respect to the sliding seat ( 24 ).
[0019] The cover ( 23 ) preferably is made of a resilient material so that the cover ( 23 ) is deformable when receiving a force. Besides, the cover ( 23 ) has a groove ( 231 ) defined in an upper portion thereof so that when the cover ( 23 ) is receiving a force, the cover ( 23 ) is folded along the groove ( 231 ) to open the through hole ( 22 ).
[0020] The sliding seat ( 24 ) includes two oppositely formed ledges ( 241 ) each having a notch ( 2411 ) defined therein, a recessed area ( 242 ) centrally formed on the sliding seat ( 24 ) and a limiting groove ( 243 ) defining in a top portion of a bottom face defining the recessed area ( 242 ). Two tracks ( 244 ) respectively formed between one of the two ledges and a top face of the sliding seat ( 24 ).
[0021] The position plate ( 25 ) includes two oppositely formed side walls ( 251 ) each having a position ear ( 2511 ) integrally extending out therefrom to correspond to the notches ( 2411 ) and a truncated edge ( 2512 ) formed on a lower portion of the side wall ( 251 ), a cap ( 252 ) formed between the two side walls ( 251 ), a U-shaped cut ( 253 ) defined in a lower portion of the position plate ( 25 ) to form therein a tongue ( 254 ) which has two bosses ( 2541 ) oppositely formed on a rear side face of the tongue ( 254 ) to correspond to the limiting groove ( 243 ). It is noted that the position plate ( 25 ) has two extensions ( 255 ) oppositely formed on the position plate ( 25 ) to correspond to the tracks ( 244 ) of the sliding seat ( 24 ).
[0022] It is to be noted that the body ( 20 ) has a flange ( 200 ) which is to be securely connected to a side face of the air-cushioned bed by any appropriate method known in the art. Therefore, when the body ( 21 ) is received in the concave space ( 11 ) (as shown in FIG. 1), the connection between the flange ( 200 ) of the body ( 21 ) and the side face of the air-cushioned bed ( 10 ) is air tight and the through hole ( 22 ) communicates with the interior of the air-cushioned bed.
[0023] With reference to FIGS. 3 and 4 and still taking FIG. 2 for reference, after the air blower ( 30 ) is received in the body ( 21 ) and after the position plate ( 25 ) is connected to the sliding seat ( 24 ), the movement of the two extensions ( 255 ) along the corresponding tracks ( 244 ) allows the position plate ( 25 ) to slide into the body ( 21 ). Furthermore, the sliding seat ( 24 ) is so defined that when the position plate ( 25 ) is moved downward into the body ( 21 ), the tongue ( 254 ) is slightly abutted by the bottom face of the recessed area ( 242 ) due to the bosses ( 2541 ). Due to the design of the recessed area ( 242 ), as the position plate ( 25 ) continues to move downward into the body ( 21 ), the tongue ( 254 ) will be slightly tilted. In the meantime, while the position plate ( 25 ) is moving downward into the body ( 21 ), the truncated edge ( 2512 ) engages with the first annular flange ( 311 ) and gradually pushes the air blower ( 30 ) to allow the second annular flange ( 321 ) to be received in the through hole ( 22 ). In order to accomplish a secure engagement of the second annular flange ( 321 ) and an inner face defining the through hole ( 22 ), the through hole ( 22 ) has a diameter slightly larger than that of the second annular flange ( 321 ) such that after the second annular flange ( 321 ) is received in the through hole ( 22 ) due to the push of the truncated edge ( 2512 ) to the first annular flange ( 311 ) of the air blower ( 30 ), the engagement therebetween is secured. After the position plate ( 25 ) is moved to reach a bottom face of the body ( 21 ), the cap ( 252 ) engages with the first annular flange ( 311 ) and the two position ears ( 2511 ) of the two side walls ( 251 ) are received in the corresponding notches ( 2411 ) to therefore position the air blower ( 30 ) inside the body ( 21 ), as shown in FIG. 5. It is to be noted that after the air blower ( 30 ) is securely received inside the body ( 21 ) and activated, the air flow from the air blower ( 30 ) moves the cover ( 23 ), which is shown in the dashed lines shown in FIG. 3. However, when the bed is to be deflated, the operator reverses the air blower ( 30 ) and still uses the cap ( 252 ) to position the air blower ( 30 ) inside the body ( 21 ). Because the inlet ( 31 ) is now in alignment with the cover ( 23 ), in order to suck the air from the bed, the operator has to move the cover ( 23 ) upward to allow the inlet ( 31 ) to communicate with the interior of the bed such that air is able to be sucked from the bed.
[0024] With reference to FIG. 6 and still using FIG. 5 for reference, after the air blower ( 30 ) is securely received in the body ( 21 ), the air blower ( 30 ) is able to inflate the air-cushioned bed ( 10 ) (in FIG. 1). It is noted that when the air blower ( 30 ) is inflating the air-cushioned bed ( 10 ), the cover ( 23 ) is blown and folded at the groove ( 231 ) so that air is able to be forced into the air-cushioned bed ( 10 ).
[0025] However, when the air-cushioned bed ( 10 ) is to be deflated, the user may force the two side walls ( 251 ) (as shown in FIG. 5) to move toward each other such that the position ears ( 2511 ) may leave the limitation of the notches ( 2411 ). Then the user may pull the position plate ( 25 ) upward to release the air blower ( 30 ). After the air blower ( 30 ) is released and removed from the casing ( 20 ), the user may reversibly place the air blower ( 30 ) back into the casing ( 20 ). That is, the inlet ( 31 ) will be facing the through hole ( 22 ) and the outlet ( 32 ) will be facing the sliding seat ( 24 ). Thereafter, the secure process to the air blower ( 30 ) by the position plate ( 25 ) is the same as what is disclosed above. The activation of the air blower ( 30 ) sucks air out of the air-cushioned bed ( 10 ) to rapidly deflate the air-cushioned bed ( 10 ).
[0026] In conclusion, with the casing ( 20 ) received in the concave space ( 11 ) in the air-cushioned bed ( 10 ) and the air blower ( 30 ) detachably received in the casing ( 20 ), the user can easily store the air blower ( 30 ) without occupying any further space than that occupied by the air-cushioned bed. Because the air blower ( 30 ) is secured by the position plate ( 25 ) inside the body ( 21 ) of the casing ( 20 ), the user need not worry that the air blower ( 30 ) will be lost due to movement of the bed, or buried under piles of clothes around the bed.
[0027] It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | An air-cushioned bed assembly includes an air bed with a concave space defined in a side face thereof, a casing received in the concave space and securely connected to the side face of the air bed. The casing has a body with a U-shaped cross section, a through hole defined in a side face of the body and a cover foldably connected to a circumference defining the through hole. An air blower is detachably received in the body of the casing and has an inlet and an outlet corresponding to the through hole of the body. A securing device is securely formed in the body to selectively retain the air blower inside the casing. Activation of the air blower facilitates air flowing into the air bed via the through hole, which folds the cover. | 0 |
This is a divisional of application Ser. No. 795,546, filed May 10,1977, and now abandoned.
BACKGROUND OF THE INVENTION
The present invention refers to an easily erectable and dismountable building of the type comprising a plurality of thin-walled sections, which are anchored to an underlying supporting frame by aid of anchoring means arranged to extend through apertures in said sections.
The invention is a method for mounting such a building.
The intended building is primarily adapted for temporary use, and appropriate fields of application can be as warehouses, workshops hangars and the like.
In earlier constructions of this type the anchoring means have been designed e.g. as hook members which could be tightened by aid of screw joints and the like. This older mode of construction has given a rather satisfactory result, but the time required for fitting and tightening the plurality of screws or bolts required for a building of ordinary size will be rather long and this means that the working costs for erecting such a building will be comparatively large. This older method of erection will also involve the risk that fretting corrosion will form between the surfaces of bolts and nuts, which will make a desired dismounting of the building difficult if and when removal of the building is desired. This drawback can make it necessary to cut off the anchoring members by aid of a welding torch or the like, which in turn will cause large risks of damaging the sections forming part of the building during the dismounting operation.
Buildings of this type are oftenly built in hangar-form i.e. the cross-section of the building is substantially semicircular. At earlier constructions of such hangar-shaped buildings from such thin-walled sections have these sections prior to mounting been given a permanent deformation to an arch-form corresponding to the form of the erected building and the sections have thereupon been mounted e.g. by aid of the adjustable anchoring members described hereabove. This means a further drawback in that the handling and transport of the bent sections will be considerably more complicated than the handling and transport of plane sections.
In U.S. Pat. 2 328 197 has been described a building structure of the kind specified in this application. The elements of this older building corresponding to the sections as hereinbefore described are bent to assume the curvature of the frame prior to being fitted thereto, but the fitting to the frame thereupon is made by means of screw or bolt joints. The resiliency of the sections is therefore not used in the manner now proposed by this application and the time necessary for fitting and tightening all the required joints will be quite long.
SUMMARY OF THE INVENTION
The purpose of the invention is to a method of erecting a building of the type specified, which is very easy to mount and dismount, and which will therefore become cheap as to mounting and dismounting costs. This is achieved thereby that each section when mounted is biased and adapted to retain the anchoring member in engagement with the supporting frame by aid of its resiliency.
The method of erecting a building of the above-identified type is characterized thereby that a first thin-walled section, provided with apertures near each one of its corners, is provided with anchoring members extending through said apertures, that the anchoring members at one side edge of said section is governed manually to engagement with a transverse struts in a supporting frame, provided with a plurality of such transverse struts which are arranged on frame portions extending in a direction differing from that of the sections in their initial, unmounted condition, that the section is bent manually against the action of its resiliency in such a manner that the anchoring members at the opposite side edge of the section by manual guidance are brought to a position in which they engage a second transverse strut arranged in parallel with said first strut, in such a manner that engagement is achieved when the manually exerted force is relieved and the section is allowed to flex against its initial extension, and that further thin-walled sections are mounted in the same manner as said first section, each further section thereby being inserted with its first end below the edge of the section mounted immediately thereabove, in such manner that overlapping is achieved at the anchoring, the apertures of the front end of said further sections thereby being provided with slots opening at the front end of the section, whereby the anchoring members mounted in the apertures at the rear end of the adjacent, mounted section will enter through said slots into said front apertures of the further section during the mounting of this, and thereupon act as the frontal anchoring members of this further section.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows in a perspective projection a hangar shaped building of the kind intended in the application.
FIG. 2 is a part view of an arch-formed portion forming part of the supporting frame of the building, and shown with a section mounted and a second section during mounting.
FIG. 3 is a view in the longitudinal direction of the section, showing a section and the associated anchoring member.
FIG.4 shows a side elevation of the anchoring member shown in FIG. 3.
FIG. 5 shows a portion of a modified embodiment of the anchoring member in a position where it is mounted to a strut of the supporting frame.
FIGS. 6 to 8 show schematically a preferred method of mounting and erecting a building according to the invention, and
FIG. 9 shows in a fragmentary side elevation a modified embodiment of the transverse strut of the supporting frame with sections mounted thereon.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 is shown a hangar-shaped building 1, which comprises a supporting frame 2 and a number of thin-walled sections 3 mounted thereon and preferably consisting of sheet metal but which sections also can be e.g. sheets of plastic material. The supporting frame incorporates in the embodiment shown a number of arch-formed members 4, and a number of transverse struts 5, 6 fitted to said arch-formed members and connecting these. The sections 3 are, as can be better seen from FIG. 2, mounted to the supporting frame by aid of specific anchoring members 7, which extend through apertures arranged near each one of the four corners of the section, and are adapted when mounted to engage with a connecting piece 8 the struts 6 of the supporting frame and thereby retain the section in position relative to said supporting frame. The figure shows how a first section has been mounted to the supporting frame, whereby the connecting pieces 8 of the anchoring members 7 have been hooked around two struts 6. It is further shown how a second section 3' just is mounted. The frontal apertures as seen in the direction of mounting in this second section have been provided with slots which extend to the frontal edge of the section. The frontal edge of this second section 3' can therefore be pushed in below the rear edge of the previously mounted section 3, the slots thereby guiding the section 3' in relation to the earlier affixed anchoring members 7, until these are situated in the apertures at the front edge of this second section 3'. At the rear edge of the second section 3' there are round apertures similar to those of the said first section 3, and these rear apertures are also fitted with anchoring members 7. As shown in FIG. 3 the section 3' during mounting will be pushed manually in the direction shown by arrow A against the supporting frame to the position shown in dash lines, and when the connecting piece 8 of the anchoring member shall snap behind the transverse strut 6 the connecting piece can be governed in the longitudinal direction of the section by manual operation from the outside of the section by means of the governing member 9 which projects upwards and can be moved along a curved path intimated with arrow B. By using a section 3, 3' such as shown which in its normal, uninfluenced condition has a curvature which differs from the curvature of the supporting frame, i.e. in the embodiment shown where the supporting frame has an arch-formed curvature is the section preferably quite straight, it is possible during mounting of the section to bias this in such a manner that its self resiliency strives to pull to the anchoring member away from the transverse strut 6, which is rendered impossible by the connecting piece 8 which is hooked around said strut. In the embodiment shown is used an arch-formed supporting frame and initially straight sections but it is of course also possible to have a straight or plane supporting frame on which is mounted initially curved sections which are pressed to engagement with the plane supporting frame. At such a design is however the advantage of an easier handling and transport as compared to sections having the same curvature as the supporting frame lost. FIG. 3 shows in a larger scale an endview of a section 3, which in the embodiment shown is corrugated. Such corrugation is however not necessary, but the section can instead be quite smooth or have another cross-section without thereby changing the function and advantages of the invention. An advantage with corrugated sections is however that it is possible to let the throughs and the crests of the wave-pattern of the corrugations on previously mounted sections act as guides for the sections which shall be mounted thereafter. This guiding possibility can be utilized both longitudinally and laterally, and it is hereby possible to guide the sections during mounting with more accuracy to correct mounting positions without the operator thereby being particularly observant or careful. As can be seen from FIG. 3 is the anchoring member 7 composed of an elongated governing member 9 situated on the outer side of the section and hook-formed connecting pieces 8 situated on the inner side of the section. The shanks of these connecting pieces 8 extend through the above mentioned apertures, which either are round or provided with open slots 10 extending to the front edge of the section, such as shown in the right hand part of the figure.
FIG. 4 shows in a side elevation more in detail the design of the anchoring member and as can be seen in this figure the governing member 9 is an angle bar. The shape and the appearance of the anchoring member can of course be modified without thereby changing the basic inventive idea, and FIG. 5 shows an example of a modified embodiment of the anchoring member, in which the governing member 9 is fixed by bolts to the connecting piece 8 proper, which furthermore has a bend which is not present in the embodiment according to FIG. 4. In this figure is furthermore shown a first section 3 and second section 3' in mounted positions, where the front edge of the second section 3' has been pushed in below the rear portion of the said first section. In order to avoid leakage of water through the apertures in the section it is possible such as shown in the figure, to provide the upper shank-portion of the anchoring member with a seal 11, which engages the outer side surface of the section and is pressed against this by means of the biasing force in the biased section. It is further shown in this figure how a locking member 12 designed as a triangular batten has been pushed in between the under side of the mounted section 3' and a portion of the transverse strut 6. This locking member will efficiently prevent external forces, e.g. gusts of wind and the like from unintended influence upon the sections such that their anchoring members will loose their engagement with the struts 6.
By means of this construction will the sections of the building be easily removeable, as soon as the locking member 12 has been removed, as it is only required that the free edge of a section is pressed against the supporting frame and that it is ascertained that the anchoring members takes part in this motion, whereupon the connecting pieces 8 by aid of the governing member 9 are brought away from the transverse strut 6, whereupon the force upon the section is relieved to let the section flex to the position of section 3' shown in FIG. 2 in continuous lines. The front edge of the section can thereupon easily be pulled out from under the rear edge of the section mounted nearest above, and this procedure can thereupon be repeated with the next section and so on. With such a mode of dismounting is the risk for damages on the components forming part of the building very remote.
In FIG. 9 is shown another embodiment adapted to prevent the sections from unintentionally being disconnected from the supporting frame, e.g. by wind pressure or the like. In this embodiment the transverse strut 6 is proper provided with a further supporting flange 17, projecting against the sections 3, 3' and adapted to be situated close to the front edge portion of a section 3' when this has been biased to its mounting position. As the supporting flange 17 does not hamper the movement of the rear end of the section 3, as soon as the front end of the second section 3' has been removed from under the rear edge of the first section 3, is it evident that such an additional flange 17 on the transverse strut 6 will efficiently substitute the triangular batten 12 shown in FIG. 5. The arrangement of an additional flange 17 which is integral with the strut will also mean that an automatic locking of the sections will be achieved upon mounting without the extra work of fitting in locking members in the form of battens or the like between the section and the strut.
In FIGS. 6 to 8 is shown in three schematic side elevations how an arch-formed portion 14, forming part of the building, is composed by several separate members 15, on which sections 13 are mounted in the manner described in connection to FIG. 2, by means of anchoring members of the type specified in the foregoing. At the erection illustrated in the three figures is preferably used hydraulic jacks 16, or similar devices by means of which the construction is raised step by step as the members 15 are affixed to the arch 14. The sections 13 are hereby mounted at the same pace as the arch members 15, and the members 15 which are detachably connected to each other e.g. by means of bolt joints, will form a complete arch as shown in FIG. 8, and the end of which can be bolted to concrete foundations bases on the ground. Mounting with aid of hydraulic jacks is known in the art, but it involves a particular advantage in connection with the erection of a building of the kind described in this application as the stress in the sections 13 can be allowed to vary, whereby the curvature of the arch is not settled by the form of the sections and the radius of curvature of the building can therefore be altered to meet different requirements or wishes.
The invention is not limited to the embodiments shown in the drawings and described in connection thereto, but modifications are possible within the scope of the inventive idea. The basic feature of the invention can thus, as mentioned above, be utilized with good result also at supporting frames having straight sides, in which case the sections to be used should be bent in one way or another to produce the required biasing force when they are adapted to the form of the supporting frame. | A method for easily erecting a building wherein the thin-walled sections are detachably fitted to frame by simple anchoring means, which can be manually brought to engagement with the frame when the sections are bent to the same curvature as that of the frame and which are secured to the frame by the resiliency of the sections when these are allowed to flex back to their initial curvature when the manual bending force is relieved. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of co-pending U.S. Provisional Patent Application Ser. No. 60/214,869, filed Jun. 28, 2000 and entitled SELF-PROPELLED AVALANCHE/MUDSLIDE CONTROL APPARATUS.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to the control of snow avalanches and mudslides. More specifically, this invention provides a self-propelled rocket and a collapsible launch stand that can be easily transported to a desired location in order to produce snow avalanches or mudslides in a controlled manner.
[0004] 2. Description of the Related Art
[0005] As used herein, the term avalanche is intended to mean a large mass of snow, ice, earth, mud, rock, or the like, that swiftly moves down an incline such as a mountain side or over a precipice.
[0006] In attempting to prevent dangerous avalanches, explosive devices are conventionally propelled into a mountainside in order to controllably initiate or trigger an avalanche, thus reducing the risk of a naturally occurring, dangerous and uncontrolled avalanche.
[0007] Conventionally, a variety of mechanisms have been used to attempt to trigger an avalanche in a controlled manner. For example, hand charges are lit and then manually thrown into the desired hillside. This method can subject personnel to risks of injury.
[0008] U.S. Pat. No. 5,872,326 discloses an apparatus for triggering an avalanche or the like. In the device of this patent, an explosive charge is made up of an explosive, a detonator, and a lighting mechanism for triggering the detonator. The explosive charge is placed in a tube with a propelling charge. A pulling element operates to trigger the lighting mechanism after the explosive charge has been propelled out of the tube.
[0009] Guns can be used to trigger an avalanche, an example of which is an avalanche launch gun, such as the “Avalauncher.” The Avalauncher operates like a gun in that a charge is shot into the air by way of an initial force, whereupon the charge travels a distance which is, at least in part, a function of the initial force that is applied to the charge.
[0010] What is needed is a self-propelled rocket, a collapsible launch stand, and method for triggering an avalanche wherein the rocket is self-propelled at a substantially constant acceleration to travel in a substantially line of sight path to a point of impact. It is against this background that various embodiments of the present invention were developed.
SUMMARY OF THE INVENTION
[0011] This invention provides a self-propelled rocket and collapsible launch stand that are easily transported by way of a snowmobile, backpack, or the like to a site whereat naturally occurring avalanches are known to occur. Upon setting up of the launch stand at an appropriate angle and the placement of a launch tube thereon, the self-propelled rocket is placed into the launch tube, a rocket motor within the rocket is ignited, and the rocket proceeds to a somewhat distant hillside to then explode and induce an avalanche thereon in a controlled manner.
[0012] As a feature of the invention, a second or redundant rocket motor may be provided such that, after a time delay that is indicative of failure of the first rocket motor to ignite, the second rocket motor ignites whereupon the rocket proceeds to a somewhat distant hillside to then explode and induce an avalanche in a controlled manner.
[0013] The self-propelled rocket moves at a constant acceleration rocket. The rocket includes a hollow cylindrical body member having an interior volume, an open top end, and an open bottom end whose exterior surface includes a plurality of flight guidance fins.
[0014] The inner volume of the hollow cylindrical body provides an upper volume and a lower volume. As a feature of the invention, a partition wall is provided to divide this interior volume into an upper volume and a lower volume.
[0015] An explosive payload is mounted within the upper volume, and a nose cone having a circular and planar tip closes the open top end of the body member. A rocket motor is mounted within the lower volume. The rocket has a center of gravity and a center of pressure that are both located on the rocket central axis and within the lower volume. The center of gravity is located closer to the open top end than is the center of pressure.
[0016] A collapsible launch stand holds the rocket in the launch tube for launching of the rocket. Adjustment of a pair of launch tube support members provides for adjustment of the rocket launch angle.
[0017] The rocket center of gravity is located closer to the cone end of the rocket than is the rocket center of pressure, and the tip of the cone is a flat plane that extends generally perpendicular to the rocket central axis; i.e., generally perpendicular to the rocket direction of flight. With these characteristics, and as a result of the rocket fins and the rocket velocity at the time that motor burnout occurs, it is ensured that upon rocket motor burn out occurring, the rocket drops in a declining trajectory downward and into the hillside.
[0018] These and other features and advantages of the invention will be apparent to those of skill in the art upon reference to the following detailed description which description makes reference to the drawing.
BRIEF DESCRIPTION OF THE DRAWING
[0019] [0019]FIG. 1 is a side view of a self-propelled rocket in accordance with the invention, the rocket internally having an explosive payload that is adapted to detonate upon impact with a slope having a propensity to naturally generate an avalanche.
[0020] [0020]FIG. 2 is a side view of a manually-lightable igniter, or fuse, that operates to ignite a rocket motor that is within the FIG. 1 rocket.
[0021] [0021]FIG. 3 is a side view of a mobile launch stand for use in positioning the FIG. 1 rocket prior to launch of the rocker, the launch stand being shown in its collapsed position.
[0022] [0022]FIG. 4 is a top view of the FIG. 3 collapsed launch stand.
[0023] [0023]FIG. 5 illustrates the FIG. 1 rocket within a launch tube that is positioned on the FIG. 3 launch stand, the launch stand now being in its opened or upright position, and the launch tube loosely resting against a pair of vertically extending support members that are a portion of the launch stand.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] The following embodiments and examples of the present invention are illustrative of the invention, and are not restrictive of the spirit and scope of the invention. Modifications that come within the meaning and range of present and after developed equivalence are to be included within the spirit and scope of the invention. While the invention will be shown and described with reference to a preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and detail may be made without departing from the spirit and scope of the invention.
[0025] Referring to FIG. 1, rocket 10 in accordance with the present invention includes a nose cone 11 , a body tube 12 that is adapted to internally hold an explosive payload 13 , a rocket motor 14 , and a plurality of external flight guidance fins 15 that are mounted on body tube 12 at the opposite end from nose cone 11 .
[0026] The rocket nose cone 11 is positioned at the top end 16 of rocket 10 , while rocket motor 14 is positioned generally at the bottom end 17 of rocket 10 . As will be explained below, explosive payload 13 is positioned toward the top end 16 of rocket 10 . When rocket 10 hits snow/mud/ground, explosive payload 13 detonates to start an avalanche in a controlled manner.
[0027] As shown in FIG. 1, nose cone 11 is generally conically-shaped and extends from an interface end 18 that is adapted to connect to body tube 12 to a top end 19 that comprises a generally flat plane that extends perpendicular the central axis 20 of rocket 10 .
[0028] The flat top end 19 of nose cone 11 is provided so that when rocket 10 physically contacts or engages the snow, mud or the ground, nose cone 11 provides a larger contact area 19 against the snow/mud/ground when compared to a non-flat top cone end, such as a conventional pointed end that terminates at a sharp tip. In one example, nose cone 11 of the present invention was about 2.75-inches long (see dimension 24 ), had a 1.5-inch diameter area at its flat top end 19 , and was formed from molded plastic.
[0029] The top end 21 of the rocket body tube 12 is mechanically coupled to the interface end 18 of nose cone 11 . Body tube 12 provides a two-part internal volume, or area 22 , for the storage of explosive payload 13 , provides a bottom end external and cylindrical surface region 23 for the attachment of a plurality of flight guidance fins 15 , and provides a lower internal volume or area 25 for housing rocket motor 14 .
[0030] Body tube 12 has a top end 21 and a bottom end 23 , and in one example, body tube 12 was a generally circular cylinder having a centrally-located axis 20 , and having a hollow interior 22 that extended therethrough. In one example, body tube 12 was 14-inches in axial length, and was made of fiber wound plastic, or like material. The bottom end 23 of body tube 12 further includes has a plurality of slots (not shown) that are adapted to receive rocket guidance fins 15 (for example, four slots for four fins 15 ). These slots extend parallel to axis 20 and are cut into the bottom end 23 of body tube 12 , each slot being, for example, {fraction (1/16)} of an inch in width. These slots can be equally spaced about the periphery of the body tube, for example at 90-degree intervals.
[0031] Furthermore, body tube 12 is adapted to house rocket motor 14 at its bottom end 23 and within lower volume 25 . In one example, body tube 12 had an outer diameter of 2.2-inches and an inner diameter of 2.1-inches, thus providing a wall thickness of 0.1-inch.
[0032] In one example, rocket motor 14 was positioned and held within the interior 22 of body tube 12 through the use of O-rings or like structures (not shown), which non-movably secure rocket motor 14 within body tube 12 .
[0033] Further, fins 15 (in one example comprising four fins made of molded plastic) are secured within the slots formed within body tube 12 through the use of an adhesive substance such as glue, or rivets or other securement means.
[0034] In order to position explosive payload 13 within body tube 12 , a rigid partition or bulkhead 30 may be positioned within the interior 22 of body tube 12 at a desired location along axis 20 . Bulkhead 30 divides volume 22 into a lower volume 25 and an upper volume 26 . Partition 30 comprises a flat and rigid disk whose plane extends generally perpendicular to axis 20 . In one example, partition 30 was a solid disk-shaped member that was positioned within body tube 12 at a desired location, and then secured within body tube 12 using, for example, rivets or an adhesive substance, such as glue.
[0035] The axial position of partition 30 is dependent upon the size of explosive payload 13 , and this positioning of partition 30 affects how rocket 10 travels after rocket motor 14 has burned out. Preferably, partition 30 is positioned between motor 14 and explosive payload 13 , and generally towards the top end 21 of body tube 12 .
[0036] Rocket motor 14 provides a means to propel rocket 10 during flight, preferably at a substantially constant acceleration with increasing velocity, in order to deliver explosive payload 13 to a desired location. In one example, rocket motor 14 was an H45W rocket motor by Aerotech Consumer Aerospace of Las Vegas this rocket motor having a 15 to 18 pound initial thrust (preferably an 18 pound initial thrust) and preferably this rocket motor operates for 7.1 seconds until burnout, with an average thrust of approximately ten pounds being distributed over the 7.1 seconds of operation.
[0037] In one example, a rocket 10 with such a rocket motor 14 traveled a distance of one mile, in an approximately line of sight flight path, when fired at a 35-degree angle relative to a horizontal plane. In one example, rocket motor 14 had an axial length of 7-inches and an outer diameter of 1.5-inches. By way of example, rocket 10 had a dimension 27 of 17.5-inches and a dimension 28 of 16.75-inches.
[0038] In order to reduce the amount of travel of rocket 10 after burnout of motor 14 occurs, and in accordance with one embodiment of the present invention, it was desirable to use fins 15 of a small size, and it was desirable to position explosive payload 13 within body tube 12 in a forward position. By reducing the amount of travel of rocket 10 after engine burnout occurs, the risk that rocket 10 will travel a substantial distance after burnout, and thereby possibly miss the desired target, is reduced. Preferably, rocket 10 travels a distance that is a function, in part, of the size of rocket motor 14 , the burn time of motor 14 , and the particular dimensions and configurations of rocket 10 .
[0039] In one example, four equally-spaced fins 15 were provided to assist rocket 10 in flying in a stable manner and in a relative straight line. Each fin 15 had an approximate thickness of {fraction (1/16)}-inch, a width of 1.365-inches (measured perpendicular to axis 20 ), and a length of 6-inches (measured parallel to axis 20 ). Each fin 15 had a slanted leading edge 31 approximately 2-inches long and a 2-inch long slanted trailing edge 32 that axially-extended approximately 1-inch beyond the bottom end 23 of body tube 12 and rocket motor 14 . This form of a slanted trailing edge 32 has been found to improve the flight stability of rocket 10 , and the slanted trailing edges 32 have been found to reduce deterioration of fins 15 due to heat generated by rocket motor 14 .
[0040] Further, in one example, explosive payload 13 was positioned relatively forward within body tube 12 , as is shown in FIG. 1, in order to reduce an amount of travel of rocket 10 after burnout of rocket motor 14 has been completed. The axial position of explosive payload 13 within body tube 12 is governed, in part, by the position of the above-mentioned partition/bulkhead 30 by the axial length of explosive payload 13 , and by the weight of explosive payload 13 .
[0041] In one example, a 8 ounce explosive payload 13 was 1⅝-inches in diameter and 4¾ inches long; and for this explosive payload 13 partition 30 was positioned 5½-inches from the top end 21 of body tube 21 , resulting in a distance traveled of 1.25 miles by rocket 10 .
[0042] In another example, a 10 ounce explosive payload 13 was 2-inches in diameter and 4¾-inches long; and partition 30 was positioned 5⅘-inches from the top end 21 of body tube 12 , to thereby produce travel distance of 1.00 miles by rocket 10 .
[0043] In another example, a 12 ounce explosive payload 13 was 2¼-inches in diameter and 4¾-inches long, partition 30 was positioned 6 inches from the top end 21 of body tube 12 , to produce a travel distance of 0.85 miles by rocket 10 .
[0044] In another example, for an explosive payload 13 of 8, 10, or 12 ounce, partition 30 was positioned at from 5¾-inch to 6¾-inch from the top end 21 of body tube 12 .
[0045] It is understood that the dimensions provided herein are by way of example only, and that the particular structure and positioning of each of the elements of rocket 10 for triggering an avalanche is a matter of choice depending upon the particular implementation.
[0046] Furthermore, the flight stability and distance that rocket 10 travels after rocket motor 14 has burned out is also governed by the relative positions of the center of pressure 34 and the center of gravity 35 of rocket 10 . Preferably, the center of pressure 34 is located on axis 20 , within lower volume 25 , and toward the bottom end 17 of rocket 10 , whereas the center of gravity 35 is located on axis 20 , within lower volume 25 , and toward the top end 16 of rocket 10 . That is, the center of pressure 34 is below the center of gravity 35 .
[0047] The axial position of the center of pressure 34 is controlled, in part, by the size of fins 15 and by the position of fins 15 along the axial length 20 of body tube 12 , by the diameter of body tube 12 , and by the shape of nose cone 11 . In one example, the rocket center of pressure 34 was 7-inches above the bottom end 23 of body tube 12 .
[0048] The position of the rocket center of gravity 35 depends, in part, on the position of explosive payload 13 within body tube 12 . Preferably, center of gravity 35 is above center of pressure 34 by a distance that is approximately equivalent to the outer diameter of body tube 12 . In one example, body tube 12 had an outer diameter of 2.2-inches.
[0049] By positioning the center of gravity 35 above the center of pressure 34 , rocket 10 of the present invention is “nose heavy.” Thus, upon burnout of motor 14 occurring, rocket 10 quickly falls to the ground, with nose cone 11 striking the ground/avalanche/mud with an acceleration that is approximately equal to the acceleration of rocket 10 before motor burn out occurred, thereby detonating explosive payload 13 .
[0050] Explosive payload 13 , in one example of the present invention, comprised a main charge 40 and a cap detonator 41 . Main charge 40 was a booster explosive having an ultra high explosive rating with a detonation velocity of approximately 26,000 feet per second. Main charge 40 , when detonated, was responsible for initiating an avalanche.
[0051] Cap detonator 41 was positioned proximate to main charge 40 , and was preferably secured to the top end of main charge 40 , as is shown in FIG. 1, toward the top end 21 of body tube 12 . Cap detonator 41 is a high explosive that ignites with as much force as is required to detonate main charge 40 .
[0052] In operation, and after rocket motor 14 has burned out, rocket 10 decelerates downward and into the ground/snow/mud, with nose cone 11 pointing down, and with nose cone 11 being the first element of rocker 10 to contact the ground/snow/mud. Because of the positioning of cap detonator 41 toward the top end 16 of rocket 10 , with main charge 40 being positioned behind cap detonator 41 , upon impact, main charge 40 (which weighs more than cap detonator 41 ) slides forward within body tube 12 and crushes cap detonator 41 . Cap detonator 41 then ignites and causes main charge 40 to detonate, which then initiates an avalanche. A small primer is associated with cap detonator 41 . This primer explodes cap detonator 41 , whereupon main charge 40 explodes. In other words, the explosion sequence comprises an impact, detonation of the primer, detonation of cap detonator 41 , and detonation of main charge 40 .
[0053] An ignition system for igniting rocket motor 14 is also disclosed herein. In one example (not shown), a conventional battery and an electric squib were used to ignite the rocket motor.
[0054] As an alternative for use where allowed by government regulation, FIG. 2 shows a fuse assembly 45 in accordance with one embodiment of the invention for igniting rocket motor 14 . Preferably, fuse assembly 45 includes a fuse portion 46 and a portion 47 of heat-shrink material that surrounds a portion of fuse 46 . Fuse 46 is preferably a black powder fuse that is made of string-like material (i.e., candlewick cotton), approximately ⅛-inch in diameter and 11¼-inches long.
[0055] The length of heat-shrink material 47 is preferably 6-inches long. A length 48 of fuse 46 is bent along the outer perimeter of heat-shrink material 47 . Because a portion of fuse 46 is contained inside of heat-shrink material 47 , once the end 59 fuse 46 is lit, fire within the lit fuse travels efficiently toward the top end 50 of fuse assembly 45 .
[0056] Furthermore, fuse 46 preferably extends from the back portion 51 of heat-shrink material 47 by approximately 10-inches, which 10-inch extension provides an ignition delay period. Fuse 49 preferably burns at a rate of approximately 1-inch every 1.4 seconds.
[0057] In one example, the top end 50 of fuse assembly 45 was dipped into a fire fluid to promote the rapid and instantaneous combustion of the top end 50 of fuse 49 proximate rocket motor 14 . It has been found that a more instantaneous and complete combustion of the top end 50 of fuse assembly 45 , proximate rocket motor 14 , promotes improved lighting and firing of rocket motor 14 . In one example, the fire fluid was an acetone-based solution generally described in “ The Chemistry of Pyrotechnics ” by John A. Conkling, 1985, the disclosure of which is expressly incorporated herein by reference.
[0058] Preferably, after the top end 50 of the assembly 45 is immersed in the fire fluid, a thin line of the fire fluid is dripped along the outer perimeter of heat-shrink material 47 , approximately half way down its length. Fuse assembly 47 is then permitted to dry.
[0059] Upon fuse assembly 45 being formed as above described, and after rocket 10 has been positioned on launch stand 55 (shown in FIGS. 3 - 5 and described below), the top end 50 of fuse assembly 45 is inserted into an opening (not shown) that is within rocket motor 14 , this opening being adapted to receive a fuse. Fuse assembly 45 can then be manually lit at the end 49 that is opposite to rocket motor 14 , in order to ignite rocket motor 14 and propel rocket 10 toward a desired target.
[0060] Referring now to FIGS. 3 - 4 , a launch stand 55 in accordance with the present invention is shown. Launch stand 55 includes a pair of parallel-extending and rigid launch tube support members 56 , about 34-inches long, whose ends 57 are pivotally coupled to the ends 58 of a pair of parallel extending and rigid positioning members 59 that are about 34-inches long.
[0061] Launch tube support members 56 are adapted to loosely support a launch tube 60 (see FIG. 5) having a rocket 10 positioned therein. In this position, the bottom end 36 of launch tube 60 rests against a pair of upright support members 37 .
[0062] At one end 61 , launch tube support members 56 are rotatably connected to a flat base plate 62 by way of a dowel pin 63 . At the other end 57 , launch tube support members 56 are rotatably coupled to positioning members 59 by way of a dowel pine 64 .
[0063] The ends 66 of positioning members 59 extend between a parallel set of rails 65 that are non-movably secured to base plate 62 . Rails 65 act as guide members on which the ends 66 of positioning members 59 can slide.
[0064] In one example, a plurality of openings 67 were provided within rails 65 to securely and adjustably position the ends 66 of positioning members 59 relative to rails 65 and base plate 62 . Alternatively, positioning members 59 can be adjustably secured to rails 65 by the use of one or more clamps (not shown).
[0065] By moving the ends 66 of positioning members 59 relative to rails 65 changes the position of the pivot point at which launch tube support members 56 are connected to positioning members 59 (i.e., at dowel pin 64 ). In this way, this pivot point can be moved up or down to provide various angles for launch tube 60 relative to base plate 62 .
[0066] A portion of launch tube support members 56 supports launch tube 60 , and a rocket 10 that is located therein, after launch stand 55 has been appropriately set and secured to achieve a desired angle for launch tube 60 , as shown in FIG. 5.
[0067] Launch stand 55 , preferably in the collapsed position shown in FIGS. 3 and 4, is adapted to be towed behind a snowmobile, or to be mounted in or on a stretcher that is connected to a snowmobile, so that launch stand 55 is easily moveable to a location that is susceptible to avalanches. Launch stand 55 can also be adapted to be carried using shoulder straps (not shown), or by way of a backpack.
[0068] In one example, base plate 62 of launch stand 55 was 5½ feet long and 2 feet wide.
[0069] As shown in FIG. 5, launch tube 60 is preferably a hollow cylindrical tube having a closed bottom that can be made of similar materials as body tube 12 of rocket 10 . Preferably, launch tube 60 has a 4¾-inch inner diameter, and preferably the difference between the inner diameter of launch tube 60 and the outer dimensions of rocket 10 (including fins 15 ) is 0.015-inch.
[0070] In overall operation, rocket 10 is formed and explosive payload 13 positioned at a desired location within body tube 12 . Launch stand 55 is placed and oriented in a proper position and at a proper angle for the firing of rocket 10 . Launch tube 60 is then placed on launch stand 55 , and rocket 10 is inserted within launch tube 60 . An ignition assembly 45 is then inserted into rocket engine 14 and the ignition assembly is activated; for example, a fuse is lit. After rocket motor 14 is ignited, rocket 10 travels, in one example, with substantially constant acceleration and in a substantially straight line of sight. When rocket motor 14 burns out, rocket immediately 10 falls and hits the ground/snow/mud. Due to the inertia that is created by the force of rocket motor 14 , main charge 40 now slides forward within body tube 12 and crushes cap detonator 41 and its primer, thus igniting cap detonator 41 , and thus detonating main charge 40 . The resulting explosion then triggers an avalanche.
[0071] It is believed that the blast created by rocket 10 is directional and in the same direction as the flight of the rocket. If desired, main charge 40 may be constructed and arranged to provide a desired direction of blast upon impact.
[0072] While the present invention has been described and shown in terms of a rocket 10 having particular dimensions and an explosive payload 13 having particular weights and dimensions, and a fuse assembly 45 and a launch stand 55 having particular characteristics, it is understood that these details are by way of example only and that changes in rocket 10 , explosive payload 13 , fuse assembly 45 , and/or launch stand 55 are a matter of choice within the spirit and scope of the invention.
[0073] [0073]FIG. 6 is a partially sectioned view of the explosive payload 13 assembly. A percussion primer 41 A and a shock tube 41 B interact with the high-explosive main charge 40 as described.
[0074] [0074]FIG. 7 is an end view of launch tube 60 A with a rocket 60 A in place. In this particular example, guide rails 81 - 84 run the length of tube 60 A and support the outer periphery of rocket 10 A during its outward travel although these rails are somewhat spaced from the rocket IOA outer surface. Supports members 81 - 84 are preferably offset from fins 15 as shown.
[0075] If desired, a secondary or redundant explosive charge can be included within the body of rocket 10 . This charge could be located at the top end of the rocket motor and configured to explode a predetermined time period after impact or launch of the rocket. The rocket would then be buried in the snow, mud, etc. and produce the desired end result. Thus, if the explosive payload 13 should fail, the secondary charge would detonate after the time delay exploding both itself and the primary payload 13 . Conversely, the secondary charge could likewise be detonated by payload 13 when it successfully detonates.
[0076] While the methods disclosed herein has been described and shown with reference to particular steps performed in a particular order, it will be understood that these steps may be combined, sub-divided, or re-ordered to form an equivalent method without departing from the teachings of the present invention. Accordingly, unless specifically indicated herein, the order and grouping of the steps is not a limitation of the present invention. | A self-propelled and constant-acceleration rocket for use in triggering an avalanche includes a hollow cylindrical body member having an interior volume, an open top end, and an open bottom end whose exterior surface includes a plurality of flight guidance fins. A partition wall divides the interior volume into an upper volume and a lower volume. An explosive payload is mounted within the upper volume, and a nose cone having a circular and planar tip closes the open top end of the body member. A rocket motor is mounted within the lower volume. The rocket has a center of gravity and a center of pressure that are both located on the rocket's central axis and within the lower volume. The center of gravity is located closer to the open top end than is the center of pressure. A collapsible launch stand holds the rocket in a launch tube for launching of the rocket. Adjustment of a pair of launch tube support members provides for adjustment of the rocket's launch angle. | 5 |
BACKGROUND OF THE INVENTION
The present invention generally relates to improvements in high aspect ratio etching and, in particular, relates to reverse masking profiling to provide a more uniform mask height between the array and periphery portions of a memory cell to mitigate twisting during high aspect ratio etching.
Today's semiconductor-based integrated circuits and micro-electro-mechanical systems (MEMS) are pushing the limits of many deep etch processes with their need for increasingly deeper and narrower contacts that have aspect ratios greater than 40:1. High aspect ratio (HAR) etching could be key in the future development of devices with high device/feature densities on a semiconductor wafer such as, for example, dynamic random access memory (DRAM) container capacitors and FLASH contacts.
However, as the aspect ratio of the plasma etch increases, twisting is increasingly becoming an issue. “Twisting” is the lateral offset of the bottom of an etched feature from the top. In a cross section, the twisted features bends in the X or Y direction, i.e., to the left and right of the page (X-direction) or in and out of the page (Y-direction). During plasma etching, as the aspect ratio increases, twisting becomes more common. The twisting is caused by asymmetric feature charging, which results in a lateral electrical field. In general, feature charging is due to the electrons having an isotropic velocity distribution, i.e., the thermal velocity is larger than the directed velocity, while the ions have an anisotropic velocity distribution, i.e., the directed velocity is much larger than the thermal velocity. For ions, the directed velocity is normal to the wafer, due to their acceleration by the plasma sheath. This means that most of the electrons will deposit their charge near the top of an HAR feature while the ions deposit their charge more toward the bottom. This results in the top of the feature charging negatively and the bottom positively. If this vertical charging becomes azimuthally asymmetric than the lateral electric field results, causing twisting. Asymmetric charging is caused by asymmetric mask geometry, which results in different view angles for electron and ion fluxes at different locations around the circumference of the contact or container. Differential electric charge builds up on the mask, causing local distortion of the ion trajectory at the edge of the array. This is often stochastic in the array, due to small variation in polymer deposition or lithographic induced asymmetries. At the edge of the array, systematic twisting is frequently observed, wherein the last several (up to 40) features twist in the direction of the edge of the array. One common, and problematic, example of twisting is in a DRAM container oxide etches. During oxide etching, twisting can result in “open” capacitors when the DRAM container does not land on the contact. Alternatively, twisting can cause shorts (doublebits) when two containers twist together.
Theory and computer simulation have shown that the twisting at the edge of the array is caused by different hard mask heights between the periphery and array portions of the semiconductor wafer. As described below, the different mask heights are caused by the faceting of the hard mask. The different mask heights result in a lateral electric field toward the periphery. This electric field pushes ions in the same direction. It is believed that this causes, or at least contributes, to the systematic twisting seen toward the moat at the edge of the array. In other words, for plasma etching with a strong ion energy component, i.e., the etch is as much or more physically driven than it is chemically driven, facets naturally develop because the peak angular yield of incident ions occurs at off-normal incidence. Typically, this is about 60 degrees. Oxide etch chemistries are typically done at high bias and the dominant ion is argon (Ar+). This means that the oxide etch ions are, in fact, quite physically driven, and prone to faceting.
In the array, the facets “come together” due to the small critical dimension of the space (the “line”) between the dynamic random access memory (DRAM) containers. In doing so, the etch rate of the mask in the array is naturally increased as compared to etch rate of the open, peripheral areas due to these geometric considerations. In addition, the difference in open area (i.e., the area to be etched) in the array versus the open area in the periphery contributes to a loading difference that tends to increase the mask loss in the array as compared to periphery. These two effects together result in less mask remaining in the array portion of the semiconductor wafer than in the periphery portion toward the end of a high aspect ratio etch. It is at the time that the systematic twisting typically occurs.
Therefore, it is important to reduce the relative height differential between array and periphery, which results in a lateral electric field and, therefore twisting. This could be done by reducing the faceting of the mask during high-aspect-ratio etches. However, the problem is overconstrained and the high bias and chemistries needed to drive an oxide etch at high aspect ratios results in a fairly fixed level of mask faceting and, therefore, result in a difference in mask height between the periphery and the array.
Therefore, there is a need to provide a solution to the problem of twisting at the edge of an array portion of a semiconductor wafer during high aspect ratio etching by reducing the difference in mask heights between the periphery and the array.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The following detailed description of specific embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:
FIG. 1 is a schematic top plan view of a memory device according to an embodiment of the present invention.
FIGS. 2-6 are schematic cross-sectional views of the formation of a masking level according to an embodiment of the present invention.
FIGS. 7A-C are schematic cross-sectional views of the formation of a masking level according to another embodiment of the present invention.
DETAILED DESCRIPTION
In the following detailed description of the embodiments, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration, and not by way of limitation, specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and that logical, mechanical and electrical changes may be made without departing from the spirit and scope of the present invention.
The term ‘substrate’ is to be understood as a semiconductor-based material including silicon, silicon-on-insulator (SOI) or silicon-on-sapphire (SOS) technology, doped and undoped semiconductors, epitaxial layers of silicon supported by a base semiconductor foundation, and other semiconductor structures. Further, in the discussion and claims herein, the term ‘on’ used with respect to two layers, one ‘on’ the other, means at least some contact between the layers, while ‘over’ means the layers are in close proximity, but possibly with one or more additional intervening layers such that contact is possible but not required. Neither ‘on’ nor ‘over’ implies any directionality as used herein.
Referring initially to FIG. 1 , a top view of an integrated circuit 100 such as, for example, a memory cell is illustrated. A central region 110 of the integrated circuit 100 , the “array,” is surrounded by a peripheral region 120 , the “periphery.” The array 110 is typically densely populated with conducting lines and electrical devices such as, for example, transistors and capacitors. The periphery 120 typically is comprised of features larger than those found in the array 110 . Consequentially, typically, high aspect ratio etching is performed in the array 110 , whereas low aspect ratio is performed in the periphery 120 . Alternatively, the periphery 120 may contain no features for a given masking level.
Referring to FIG. 2 , a layer of amorphous carbon 200 is deposited over a substrate 210 . Typically, the amorphous carbon layer 200 can have a thickness of about 4000 Å to about 10000 Å. As shown in FIG. 3 , a hard mask layer 400 is then deposited over the amorphous carbon layer 200 . This hard mask layer can be an inorganic material such as, for example, silicon oxynitride anti-reflective coating (SiON ARC). This hard mask layer 400 typically have a thickness of between about 200 Å to about 500 Å. Typical photolithography can then be performed where a bottom anti-reflective coating (BARC) (not shown) can be deposited over the SiON ARC layer 400 to control light reflections. As shown in FIG. 4 , a photodefinable material layer 410 is deposited on the BARC and SiON ARC 400 layers. The photodefinable material 410 typically can have a thickness of between 500 Å to about 1500 Å. The photodefinable material 410 can be photoresist material or any other suitable photodefinable material known in the art. The array 110 is then patterned with, for example, contacts and containers. The photodefinable material layer 410 can then be exposed and developed. The BARC layer can be consumed, leaving the SiON ARC layer 400 over the amorphous carbon layer 200 . Photolithography is again performed leaving another layer of photodefinable material layer 500 over the array and exposing the periphery 120 . The SiON ARC layer 400 can be then etched away from the periphery 120 portion as shown in FIG. 5 .
As shown in FIG. 6 , a portion of the amorphous carbon layer 200 can then be etched away in the exposed periphery 120 portion resulting in a thicker layer of amorphous carbon 200 in the array 110 portion than the periphery 120 . Typically, approximately half of the thickness of the layer of amorphous carbon 200 is etched away in the periphery 120 portion. For example, if the original amount of amorphous carbon deposited over the substrate 210 is 8000 Å, approximately 4000 Å would be etched away in the periphery 120 portion. The photodefinable material layer 500 can have a thickness that is approximately equal to the amount of amorphous carbon etched from the periphery 120 . This photodefinable material thickness is due to the fact that the photodefinable material layer 500 etches at least as fast as the amorphous carbon 200 . For example, if approximately 4000 Å amorphous carbon is to be etched, the photodefinable material layer 500 can have a thickness of approximately 4000 Å.
A portion of the amorphous carbon layer 200 remains over the periphery 120 after etching. The amount of the amorphous carbon layer 200 remaining is adjusted depending on the consumption of the amorphous carbon layer 200 during the HAR etch such that the heights of the array 110 and the periphery 120 matched toward the end of the HAR plasma etch. The photodefinable material layer 500 is exposed and developed away through exposure to light at the appropriate wavelength.
Typical HAR plasma etch can then be performed. The SiON layer 400 remaining over the amorphous carbon layer 200 in the array 110 will be consumed during the HAR plasma etch resulting in the layer of amorphous carbon 200 of variable thickness covering entire surface of the substrate 210 . However, by the end of the HAR plasma etch, the amorphous carbon layer 200 will have approximately the same thickness over the entire surface of the substrate 210 . Alternatively, a fill material may be used over the layer of amorphous carbon 200 in the periphery 120 before the start of the HAR plasma etch in order to reduce any topography issues caused by the varying thickness of the amorphous carbon layer 200 . It will be appreciated that the layers described above can be formed by various methods known in the art. For example, chemical vapor deposition can be used to form the hard mask layers, spin-on-coating processes can be used to form the photodefinable material layers, and the amorphous carbon layer 200 can be formed by chemical vapor deposition using a hydrocarbon compound, or mixtures of such compounds, as carbon precursors.
At the start of the high aspect ratio plasma oxide etch, the layer of amorphous carbon 200 will be thicker over the array 110 portion of the substrate 210 than over the periphery 120 portion. However, this thinner amount of amorphous carbon 200 in the periphery 120 does not cause issues due to the fact the amorphous carbon 200 etch rate in the periphery 120 portion, as mentioned above, is lower than in the array 110 portion. At the end of the high aspect ratio plasma oxide etch, the mask heights in the periphery 120 and the array 110 portions should be similar. In other words, the amount of the amorphous carbon layer 200 remaining over the periphery 120 portion results in a more uniform mask height between the array 110 and periphery 120 portions at the end of high aspect ratio plasma oxide etching. This more uniform mask height across the memory device reduces the lateral charging difference and, therefore, mitigates twisting toward the moat at the edge of the array 110 portion.
Alternatively, both the BARC layer and the SiON ARC layer 400 can be etched after the array 110 has been patterned, leaving only the layer of amorphous carbon 200 over the substrate 210 . In this embodiment, after a portion of the amorphous carbon layer 200 is etched away in the periphery 120 as seen in FIG. 7A , another photodefinable material layer/photolithography process step can occur which exposes the amorphous carbon layer 200 in the array portion 110 while leaving a layer of photodefinable material 700 over the amorphous carbon 200 in the periphery portion 120 as illustrated in FIG. 7B . Another layer of inorganic material 710 such as, for example, SiON ARC, can then be used as a hard mask 710 to etch the amorphous carbon 200 in the array 110 while the photodefinable material layer 700 protects the periphery 120 from further etching as illustrated in FIG. 7C . Normal HAR plasma etch can then occur. The amount of amorphous carbon 200 and photodefinable material 710 over the periphery 120 can be adjusted to equalize the mask height of the material in the array 110 and the periphery 120 after the end of the HAR etch. Again, it will be appreciated that the layers described above can be formed by various methods known in the art. For example, chemical vapor deposition can be used to form the hard mask layers, spin-on-coating processes can be used to form the photodefinable material layers, and the amorphous carbon layer 200 can be formed by chemical vapor deposition using a hydrocarbon compound, or mixtures of such compounds, as carbon precursors.
It is noted that terms like “preferably,” “commonly,” and “typically” are not utilized herein to limit the scope of the claimed invention or to imply that certain features are critical, essential, or even important to the structure or function of the claimed invention. Rather, these terms are merely intended to highlight alternative or additional features that may or may not be utilized in a particular embodiment of the present invention.
Having described the invention in detail and by reference to specific embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. More specifically, although some aspects of the present invention are identified herein as preferred or particularly advantageous, it is contemplated that the present invention is not necessarily limited to these preferred aspects of the invention. | A method of improving high aspect ratio etching by reverse masking to provide a more uniform mask height between the array and periphery is presented. A layer of amorphous carbon is deposited over a substrate. An inorganic hard mask is deposited on the amorphous carbon followed by a layer of photodefinable material which is deposited over the array portion of the substrate. The photodefinable material is removed along with the inorganic hard mask overlaying the periphery. A portion of the amorphous carbon layer is etched in the exposed periphery. The inorganic hard mask is removed and normal high aspect ratio etching continues. The amount of amorphous carbon layer remaining in the periphery results in a more uniform mask height between the array and periphery at the end of high aspect ratio etching. The more uniform mask height mitigates twisting at the edge of the array. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] N/A
BACKGROUND
[0002] The present invention is generally directed to the implementing a security solution using a layering system. A layering system is a tool that enables an operating system, user applications, and user data to be layered on the user's computing device. When using a layering system, layered applications and data are executed natively on the user's computing device without the use of a virtual machine or other sandboxed execution environment. This native execution will therefore cause the layered applications to appear, both to the user and to other applications, as if they were being executed in a “normal” manner. This is in contrast to many types of virtualization techniques such as terminal services and application virtualization where it is typically clear that the applications are executed in a separate environment.
[0003] U.S. patent application Ser. Nos. 14/719,248 and 14/719,256 are both directed to a layering system and provide a background for the present invention. The content of these applications is therefore incorporated by reference. It is noted that both of these applications are commonly owned and would not constitute prior art to the present invention. Therefore, this background should not be construed as admitting prior art, but should be construed as describing various features on which the present invention is based and that may even form part of the present invention.
[0004] As is described in the '248 and '256 applications, a layer is a collection of data or resources which enables the collection to be isolated or set apart from the data or resources in another layer. To summarize this layering, FIG. 1 provides simplified examples of a user data layer 101 and an application layer 102 . It is noted that a layer containing an operating system may also exist. Each layer can be stored in a manner that allows the layer to be separately mounted for access. For example, each layer may comprise a separate partition of a disk (including of a virtual disk). The ability to separately mount a layer allows the layering system to selectively provide access to particular layers. It will be assumed that the layering system determines that user data layer 101 and application layer 102 should be mounted in response to the user logging in to a computing device on which the layering system executes or which the layering system otherwise controls.
[0005] As shown in FIG. 1 and for simplicity, application layer 102 includes a single application, WINWORD.EXE, which is the executable for Microsoft Word. Word also requires a number of registry settings to execute properly, and therefore, application layer 102 also includes such registry settings. It is noted that these registry settings, which would normally be stored within the registry of the operating system, could be stored within application layer 102 in a registry hive. Of course, a typical installation of Word would require a number of other files and/or settings which are not depicted. Application layer 102 also includes layer metadata which describes the content of application layer 102 (e.g., which describes that the layer includes WINWORD.EXE and whatever structure is used to store the Word registry settings). This layer metadata is critical because it allows the layering system to quickly determine what exists on the layer.
[0006] User data layer 101 is structured in a similar way. However, as a user data layer, it stores the user's files which in this case constitute two Word documents: Report.docx and Summary.docx. As with application layer 102 , user data layer 101 may also store a number of other files including configuration files that may be particular to this user (e.g., a template file for Word). User data layer 101 also includes layer metadata which defines the content of the layer. Again, this layer metadata is critical because it allows the layering system to quickly determine what exists on the layer.
[0007] As mentioned above, a layer can be a separately mountable portion of a storage device (whether physical or virtual) such as a partition. Accordingly, when the user logs on to a computing device, the layering system can mount layers 101 and 102 so that the user will have access to MS Word and his documents which are included in these layers. However, if a different user were to log in to the same computing device, the layering system could instead mount an application layer and user data layer pertaining to the different user so that the different user can only access the applications and user data defined in those layers.
[0008] The process by which the user accesses the data and resources included on each layer is provided in the '248 and '256 applications and will not be described in detail in this specification. By way of an overview, the layering system includes a file system filter driver and a registry filter driver which can function to intercept and redirect file system and registry operations as appropriate. In particular, these filters can be registered with the OS so that they will receive all file system and registry operations respectively. If a file system or registry operation pertains to content of a layer rather than to content of the file system or registry directly provided by the OS, the filters can redirect the operation to the corresponding layer. The '248 and '256 applications provide a number of examples of this type of redirection.
[0009] The result of this redirection is that, from the user perspective, the files of the layers do not appear to be stored in a different manner than any other file would typically be stored by the OS. For example, if the user data layer 101 were assigned a partition of E:, the layering system could cause the files to appear as if they were stored in the typical C: partition. In other words, the fact that multiple partitions may be loaded is abstracted (and even hidden) from the user perspective. It is again reiterated that the use of layer metadata to define what is stored on each layer allows this process to be carried out efficiently as is described in the '248 and '256 applications.
[0010] FIGS. 2A and 2B each illustrate an example of how the layering system can function. Each of these examples involve the layering file system filter driver (or LFFD) 201 and its role in determining whether to redirect a file open request. It is noted that a similar process would be carried out by the layering registry filter driver (or LRFD) if the operation pertained to the registry.
[0011] As shown in FIGS. 2A and 2B , it will be assumed that the operating system provides a file system 200 for handling I/O to the various mounted partitions. It will also be assumed that the operating system has mounted a C: partition and that the layering system has mounted an E: partition that corresponds to user data layer 101 . In the following description, the E: partition and user data layer 101 (or simply layer) will be used interchangeably). However, it is noted that a partition is not the only structure that can be employed for a layer. It is also important to note that because the E: partition was mounted by the layering system, it will not appear in the same manner as the C: partition. In particular, the user will not be able to see the separate E: partition. Instead, the layering system may cause the contents of the E: partition to appear as if they were stored on the C: partition.
[0012] Accordingly, if the user selects to open the Report.docx file that is stored on the E: partition, a file open request 210 of C:\Docs\Report.docx may be generated. As is described in the '248 and '256 applications, LFFD 201 is registered as a filter driver for file system 200 and therefore will receive the opportunity to evaluate file open request 210 . LFFD 201 can evaluate the target of file open request 210 against the layer metadata of the E: partition (and possibly against layer metadata of any other mounted layer) to determine if the request pertains to the layer. In this case, it will be assumed that the layer metadata indicates that the E: partition includes the path \Docs and that the Report.docx file is stored in the path. As a result, LFFD 201 can modify file open request 210 to create modified file open request 210 a of E:\Docs\Report.docx. Modified file open request 210 a is then passed to file system 200 which will open Report.docx from the appropriate location on the E: partition. LFFD 201 can perform this type of rerouting for any I/O that pertains to content stored on the E: partition. The determination of whether I/O pertains to content on a particular layer is based on the layer metadata for that particular layer.
[0013] FIG. 2B illustrates the case where LFFD 201 determines that a file open request 220 does not pertain to a layer (or at least does not pertain to a layer separate from the layer that includes the operating system). In this example, file open request 220 is directed to File.txt which is stored in a Downloads folder that is assumed to exist on the C: partition. Upon receiving file open request 220 , LFFD 201 will evaluate the request against the layer metadata for the E: partition and determine that the E: partition does not include a path of \Downloads. Accordingly, LFFD 201 can allow file open request 220 to pass to file system 200 without modification since the request already includes the correct path to File.txt.
[0014] To summarize, LFFD 201 selectively modifies I/O requests so that they are directed to the appropriate layer. In the case of registry access, the LRFD would perform similar functionality to ensure that the registry access is directed to the appropriate layer. It is again reiterated that this rerouting is necessary because the layering system causes the layers to be hidden from the user's perspective while still being visible to the operating system.
BRIEF SUMMARY
[0015] The present invention extends to methods, systems, and computer program products for implementing a security solution using a layering system. By using a layering system, any changes that are made to a computing system can be isolated within a separate write layer. Due to this isolation, the changes, which may even be malicious, can be evaluated without fear that the resources in another layer or layers will be negatively affected. In this way, even security threats that are still unknown to antivirus solutions (so-called zero-day attacks) can be prevented from harming the system.
[0016] In one embodiment, the present invention is implemented on a computing device on which at least one frozen layer and a write layer are mounted and in which a layering driver causes resources on the at least one frozen layer and the write layer to appear as if the resources were stored in the same storage location. The computing device can be configured to provide a security solution using a layering system that includes a layering driver. When the layering driver receives an I/O request, it can access layer metadata of the at least one frozen layer to identify to which frozen layer the I/O request is directed. The layering driver can also determine that the I/O request pertains to an attempt to create or update a resource on the identified frozen layer. The layering driver can then modify the I/O request to direct the I/O request to the write layer such that the resource is added to the write layer rather than being added to or updated on the identified frozen layer.
[0017] In another embodiment, the present invention is implemented as computer storage media storing computer executable instructions which when executed by one or more processors of a computing device perform a method for providing a security solution using a layering system. The method can include: receiving, at a layering driver, an I/O request that is directed to a frozen layer; determining that the I/O request pertains to an attempt to create or update a resource on the frozen layer; and modifying the I/O request to direct the I/O request to a write layer such that the resource is added to the write layer rather than being added to or updated on the frozen layer.
[0018] In another embodiment, the present invention is implemented as a computing device for implementing a security solution using a layering system. The computing device can include one or more processors; one or more frozen layers that are mounted on the computing device; a write layer that is mounted on the computing device; and computer storage media storing a layering driver and a layering security system. When the one or more processors execute the layering driver, the layering driver performs the following: receive I/O requests; determine to which of the one or more frozen layers or the write layer each I/O request is directed; and upon determining that an I/O request is directed to a frozen layer and pertains to an attempt to update or add a resource on the frozen layer, modify the I/O request to cause the I/O request to be directed to the write layer. Also, when the one or more processors execute the layering security system, the layering security system evaluates any resource stored on the write layer to determine whether the resource is malicious.
[0019] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
[0021] FIG. 1 illustrates simplified examples of layers of a layering system;
[0022] FIGS. 2A and 2B generally illustrate how a layering system can reroute file system or registry operations based on layer metadata of a mounted layer;
[0023] FIG. 3 illustrates the architecture of a layering system that can be employed to provide a security solution;
[0024] FIG. 3A illustrates an alternate architecture of a layering system that can also be employed to provide a security solution;
[0025] FIGS. 4 and 5 each illustrate an example of how a layering driver can cause an I/O request that is directed to a frozen layer and pertains to an attempt to update or add a resource on the frozen layer can be redirected to a write layer;
[0026] FIGS. 6A and 6B illustrate an example of how a write layer can become a frozen layer;
[0027] FIGS. 7A and 7B illustrate an example of how multiple frozen write layers can be merged;
[0028] FIGS. 8A and 8B illustrate an example of how a frozen write layer can be merged with one or more of an operating system layer, an application layer, or a user data layer; and
[0029] FIG. 9 illustrates a flowchart of an example method for providing a security solution using a layering system.
DETAILED DESCRIPTION
[0030] In this specification and the claims, a layer should be construed as any mountable storage area including a hard disk (whether physical or virtual), a network share, or a folder. In many embodiments, a layer can be in the form of a vdisk/VHD that is streamed from a server to a client where it is mounted for use. In some embodiments, the present invention can be implemented when a client device employs an operating system layer, an application layer, and a user data layer that are each separate from one another. However, in other embodiments, a single layer containing the operating system, applications, and user data may be employed. Accordingly, the present invention should not be limited by the number or type of layers that are employed to store these resources.
[0031] Also, in this specification and the claims, the term “layering drivers” will generally refer to one or more file system filter drivers and one or more registry filter drivers which are employed to implement layering as was introduced in the background. These layering drivers, as filter drivers, will be positioned “below” the I/O manager or registry configuration manager (at least in Windows-based implementations) where they can intercept and evaluate I/O requests (or more particular IRPs generated by the I/O manager) or registry requests respectively. The term “layering security system” will generally refer to any components that can provide any type of I/O-based or registry-based security. For example, a layering security system can include one or more filter drivers that evaluate I/O requests to determine whether the I/O requests are indicative of malicious actions. In the following description, examples where the layering drivers are file system filter drivers will be provided. However, the same functionality can be provided by registry filter drivers.
[0032] FIG. 3 provides an overview of how a computing device can be configured to implement a security solution using a layering system while FIG. 3A illustrates an alternate configuration that could equally be employed. In FIG. 3 , it is assumed that an OS layer 302 a , an applications layer 302 b , a user data layer 302 c , and a write layer 302 d have all been mounted for use on the computing device. For example, in some embodiments, each (or at least one) of layers 302 a - 302 d could represent a vdisk/VHD that is streamed from a server. However, any of layers 302 a - 302 d could also be in the form of a physical drive, folder, network share, or other mountable structure. For purposes of the following examples, it will be assumed that OS layer 302 a has been assigned drive letter C:, application layer 302 b has been assigned drive letter D:, user data layer 302 c has been assigned drive letter E:, and write layer 302 d has been assigned drive letter F:. However, from the user's perspective and due to layering drivers 300 , it will appear as if there is a single drive (e.g., a C: drive) on which the resources from each layer are stored. In contrast, FIG. 3A represents a case where the computing system includes a typical operating system partition (or layer) 312 on which applications are installed and user data is stored. Although the configuration shown in FIG. 3A will not be described in detail, it is to be understood that the present invention could be implemented in the same manner described below in this configuration as well as in any other configuration that employs more than a single layer to provide the operating system, applications, and/or user data.
[0033] As also shown in FIG. 3 , a layering security system 301 may be positioned “below” layering drivers 300 and can be tasked with performing various I/O-based security tasks such as, for example, evaluating any actions taken by a downloaded application to determine whether it is malicious as will be further described below. In some embodiments, layering security system 301 may also implement various types of common antivirus protections for all resources in any layer. In other words, layering security system 301 can provide a full set of malware protections so that it will not be necessary to install a separate antivirus program. In other embodiments, however, a separate antivirus or other security solution can be used in combination with layering security system 301 .
[0034] As was described in the background, layering drivers 300 can be configured to cause the resources on layers 302 a - 302 d to appear as if they were stored on the same storage medium (e.g., as if they were all stored within the same partition of the computing device's physical hard drive). This is accomplished by redirecting or mapping I/O requests to the appropriate layer based on the target resource of each I/O request. With reference to the configuration shown in FIG. 3A , layering drivers 300 would not need to perform this type of mapping for read requests to content on operating system partition 312 (i.e., this content could be read in a normal manner).
[0035] In the following description, the term “frozen layer” will be employed to reference a layer which layering drivers 300 treat as read-only. For example, each of layers 302 a - 302 c and partition 312 can be viewed as a frozen layer since, as will be described below, layering drivers 300 prevent these layers from being updated (at least during the normal I/O process).
[0036] In accordance with embodiments of the present invention and regardless of the number of layers used to provide the operating system, applications, and user data, this layering technique can be employed to implement a security solution in which any I/O request that attempts to add a resource to or update a resource on a frozen layer is instead directed to write layer 302 d where the added/updated resource will be isolated from the resources on the frozen layer(s). For example, OS layer 302 a , application layer 302 b , and user data layer 302 c can be frozen (i.e., prevented from being modified) by redirecting any I/O request that would otherwise modify these layers to write layer 302 d . Similarly, OS partition 312 can be frozen by redirecting any I/O request that would otherwise modify content on OS partition 312 to write layer 302 d . Accordingly, FIGS. 3 and 3A each illustrate that a read only path exists for accessing layers 302 a - 302 c and partition 312 respectively while a read/write path exists for write layer 302 d . Each of these paths can “pass through” layering security system 301 thereby allowing the layering security system to perform any appropriate evaluation on the I/O requests.
[0037] FIG. 4 , which is based on the configuration depicted in FIG. 3 , illustrates how layering drivers 300 can cause any new or updated resource to be stored within write layer 302 d so that the changes are isolated from layers 302 a - 302 c . Isolating the changes in this manner can allow layering security system 301 to detect any malware that may be included in the new or updated resource before the malware would have access to the resources on layers 302 a - 302 c . It is noted that this same process could be performed in a system that is configured as shown in FIG. 3A .
[0038] In FIG. 4 , layering drivers 300 are shown as receiving an I/O request 410 in step 1 . I/O request 410 , which in practice would typically be in the form of an IRP, is intended to represent a request to create a file “app.exe” on User1's desktop. Accordingly, I/O request 410 is shown as specifying a path of C:\Users\User1\Desktop\app.exe. As an example, I/O request 410 could have been generated in response to User1 electing to download an application to his or her desktop.
[0039] As was described in the background, layering drivers 300 can employ metadata on each layer to determine whether the path specified in I/O request 410 needs to be modified to direct the I/O request to the appropriate layer. In this example, it will be assumed that user data layer 302 c , which is the E: drive, includes the path “\Users\User1\Desktop.” Therefore, layering drivers 300 can determine that the path in I/O request 410 would need to be updated to E:\Users\User1\Desktop\app.exe.
[0040] However, in accordance with embodiments of the present invention and as represented by step 2 in FIG. 4 , layering drivers 300 can also be configured to determine whether I/O request 410 pertains to an attempt to add a resource to or update a resource on a frozen layer. After determining that I/O request 410 is directed to user data layer 302 c , layering drivers 300 can then determine whether I/O request 410 pertains to an attempt to add a resource to or update a resource on user data layer 302 c . In this example, because I/O request 410 requests the creation of the file app.exe within the Desktop folder stored on user data layer 302 c , layering drivers 300 can prevent I/O request 410 from being directed to user data layer 302 c (since user data layer 302 c is a frozen layer). Instead, layering drivers 300 can modify I/O request 410 so that the app.exe file will be created on write layer 302 d.
[0041] As shown in step 3 , layering drivers 300 can modify the path in I/O request 410 to point to write layer 302 d . In this example, the modification can include changing E: to F: so that I/O request 410 will be directed towards write layer 302 d rather than user data layer 302 c . As a result, and as represented by step 4 , app.exe will be stored on write layer 302 d rather than user data layer 302 c . Although not shown, as part of modifying the path of I/O request 410 , layering drivers 300 can also cause metadata of write layer 302 d to be updated to reflect the addition of app.exe on write layer 302 d at the \Users\User1\Desktop\ path to thereby facilitate the subsequent retrieval of app.exe from write layer 302 d . It is noted that a similar process would be performed whenever any new resource is created such as when a file is downloaded from the internet, an email is received, or the user creates a new file using an existing application.
[0042] FIG. 5 provides an example similar to that of FIG. 4 except that I/O request 510 is an attempt to update a resource stored on application layer 302 b . As shown in step 1 , layering drivers 300 receive I/O request 510 . I/O request 510 is a write request to the lib.dll resource that, from the user's perspective and from the perspective of the upper level I/O components, is stored at C:\Program Files\App1\. By employing the metadata of each layer, layering drivers 300 can determine that the Program Files folder is actually stored on application layer 302 b . Therefore, layering drivers 300 can determine that the path in I/O request 510 should be updated to point to the D: drive rather than the C: drive.
[0043] However, in step 2 , layering drivers 300 can determine that I/O request 510 is an attempt to update a resource on a frozen layer (i.e., an attempt to update the file lib.dll which is stored on application layer 302 b ). Therefore, rather than modifying I/O request 510 to point to application layer 302 b , layering drivers 300 can modify I/O request 510 to point to write layer 302 d as shown in step 3 . Additionally, because the file lib.dll does not exist on write layer 302 d , it will be necessary to change the request from a write request to a create request so that the updated file lib.dll will be created on write layer 302 d . Layering drivers 300 can also update write layer 302 d ' s metadata to reflect the presence of lib.dll at the \Program Files\App1\ path. Because application layer 302 b will also include metadata identifying the presence of the lib.dll resource, layering drivers 300 may also be configured to delete this metadata from application layer 302 b or otherwise provide an indication in the metadata of either or both of write layer 302 d and application layer 302 b to define from which layer lib.dll should be accessed.
[0044] If the updates to lib.dll happen to be malicious, the malicious code will be isolated within write layer 302 d where it will likely only be able to cause minimal, if any, harm to the computing system. Additionally, while lib.dll is isolated within write layer 302 d , layering security system 301 can perform various actions to identify the presence of any malicious code and to take appropriate action to remove the malicious code and/or resource.
[0045] Accordingly, the user is able to freely add or update resources in a typical manner. However, due to layering drivers 300 , these added or updated resources will be isolated within write layer 302 d where they will not be able to harm the resources on frozen layers if they happen to be malicious. Further, due to layering drivers 300 , the fact that these resources are isolated on write layer 302 d will not be apparent to the user. From the user's perspective, the resources on write layer 302 d will appear as if they were stored on the same partition/volume as the resources on the other layers. Therefore, the user can access (e.g., read/write) the resources that are stored in write layer 302 d in a substantially normal manner (from the user's perspective).
[0046] In some embodiments, a snapshot of a write layer may be periodically taken. This snapshot could then be treated in a similar manner as any other frozen layer. In particular, when it is desired to create a snapshot, a new write layer can be created and all modifying I/O requests could then be redirected to the new write layer. The now old write layer could be frozen (i.e., treated as read-only) in the same manner as any other frozen layer.
[0047] FIGS. 6A and 6B provide an example of how write layer 302 d can become a frozen layer. As represented in step 1 in FIG. 6A , a new write layer 602 can be created. The creation of a new write layer could be performed for various reasons including manually (e.g., in response to user input) or automatically (e.g., at periodic intervals or in response to receiving a particular type of I/O request such as a request to create an executable that is being downloaded from an unknown source). Regardless of the reason for creating a new write layer, once new write layer 602 has been created, layering drivers 300 can commence redirecting any modifying I/O request to write layer 602 which in effect will cause write layer 302 d to become a frozen layer. In other words, once write layer 602 is created, layering drivers 300 will only direct non-modifying I/O requests to write layer 302 d.
[0048] FIG. 6B provides an example of how layering drivers 300 can handle I/O requests once write layer 602 is created. As shown, an I/O request 610 which requests to open the lib.dll is received. As was illustrated in FIG. 5 , lib.dll was stored on write layer 302 d in response to I/O request 510 which will be evidenced by the metadata on write layer 302 d . Layering drivers 300 will therefore determine that I/O request 610 should be modified by replacing C: with F:. Also, because I/O request 610 is a read request, layering drivers 300 will allow the I/O request to be directed to the now frozen write layer 302 d . In contrast, when layering drivers 300 receive I/O request 611 , which is a request to create a new .exe on the user's desktop, layering drivers 300 will redirect the request to write layer 602 .
[0049] One benefit of creating snapshots in this manner is that it would allow the computing system to be easily rolled back to a previous state. For example, if layering security system 301 determines that app2.exe is malicious, it could instruct layering drivers 300 to discard write layer 602 and revert to (or “unfreeze”) write layer 302 d . This would have the effect of reverting the computing system to the state that existed immediately prior to creating write layer 602 .
[0050] When the layering system is configured to create snapshots, a relatively large number of frozen layers may be created over time. Since a large number of layers may adversely impact the performance of the layering system, in some embodiments of the present invention, layering drivers 300 may be configured to merge multiple frozen layers into a single frozen layer thereby reducing the total number of layers. This can be accomplished by copying the resources and metadata from one frozen layer into another frozen layer and then discarding the layer from which the content was copied. Typically, only frozen write layers would be merged together and only after it had been determined that the contents of each frozen write layer are safe and that the ability to roll back to the state represented by the copied layer was not desired. However, it would also be possible to merge a frozen write layer with an operating system layer, an application layer, or a user data layer.
[0051] FIGS. 7A and 7B illustrate an example of how two frozen write layers can be merged. In FIG. 7A , it is assumed that a new write layer 702 has been created and that all modifying I/O requests are now being redirected to write layer 702 . Therefore, write layer 602 has become a frozen layer. Layering drivers 300 may therefore determine that it would be desirable to merge the contents of write layer 602 into write layer 302 d to reduce the total number of frozen layers from five to four. Therefore, as represented in FIG. 7B , the contents (e.g., resources and metadata) of write layer 602 can be copied to write layer 302 d such that write layer 302 d will include its original contents as well as the copied contents. After this copying of the contents of write layer 602 is completed, write layer 602 can be discarded (e.g., unmounted). Because the metadata of write layer 602 will have been copied to write layer 302 d , layering drivers 300 can employ the metadata to ensure that I/O requests to read content that was stored on write layer 602 are appropriately routed to write layer 302 d.
[0052] Although it may not be typical to do so, in some embodiments of the present invention, a frozen write layer may also be merged with an operating system layer, an application layer, and/or a user data layer. The process of merging a frozen write layer with any of these other types of layers may be performed in a slightly different manner than when combining frozen write layers as is shown in FIGS. 8A and 8B .
[0053] In FIG. 8A , it is assumed that a snapshot 800 of write layer 302 d was taken while write layer 302 d stored app.exe and lib.dll. Snapshot 800 also includes the layer metadata. In this case, this layer metadata will identify app.exe and lib.dll as well as the path to the location where they are stored. Although not shown, the layer metadata in each frozen layer (e.g., application layer 302 b and user data layer 302 c ) will also identify which files are stored in the layer as well as their paths. For example, the layer metadata for application layer 302 b could include an entry of \Program Files\App1\lib.dll which represents that the old version of lib.dll (i.e., the one that was updated in the example of FIG. 5 ) is stored on application layer 302 b . It will be assumed that the layer metadata for user data layer 302 c will indicate that the path \Users\User1\Desktop\ exists on user data layer 302 c ; however, it will not identify a file named app.exe in this path since that file never would have been created on user data layer 302 c.
[0054] As indicated in step 1 of FIG. 8A , the layer metadata in snapshot 800 can be compared to the layer metadata of each of the frozen layers to determine where each resource in snapshot 800 should be merged. For example, it can be determined that application layer 302 b includes a path \Program Files\App1\, and therefore, any resource in snapshot 800 with that same path should be merged to application layer 302 b . Similarly, it can be determined that user data layer 302 c includes a path \Users\User1\Desktop\, and therefore, any resource in snapshot 800 with that same path should be merged to user data layer 302 c.
[0055] FIG. 8B represents how the different resources in snapshot 800 can be merged in step 2 . With regards to merging lib.dll, in addition to determining that the resource should be merged with application layer 302 b , it can also be determined that a version of lib.dll already exists on application layer 302 b . Therefore, the updated version of lib.dll in snapshot 600 can overwrite the old version of lib.dll that resides on application layer 302 b . In such cases, it may not be necessary to update application layer 302 b 's metadata since the metadata will already reflect the presence of lib.dll. In contrast, the evaluation of user data layer 302 c 's metadata will reveal that there is no resource named app.exe in the \Users\User1\Desktop\ path. Therefore, app.exe can be written to user data layer 302 c and user data layer 302 c 's metadata can be updated to reflect the presence of app.exe.
[0056] Due to layering drivers 300 , these resources will be accessed in the same way (from the user perspective) whether they are stored in write layer 302 d or in the other layers. Layering drivers 300 therefore hide the underlying security solution functionality.
[0057] FIG. 9 illustrates a flowchart of an example method 900 for providing a security solution using a layering system. Method 900 can be implemented on a computing device on which at least one frozen layer and a write layer are mounted and in which a layering driver causes resources on the at least one frozen layer and the write layer to appear as if the resources were stored in the same storage location. For example, a computing device that includes layering drivers 300 and on which layers 302 a - 302 d are mounted (or on which partition 312 is mounted) could perform method 900 .
[0058] Method 900 includes an act 901 of receiving, at a layering driver, an I/O request. For example, layering drivers 300 can receive I/O request 410 or 510 .
[0059] Method 900 includes an act 902 of accessing layer metadata of the at least one frozen layer to identify to which frozen layer the I/O request is directed. For example, layering driver 300 can access layer metadata of any of layers 302 a - 302 c.
[0060] Method 900 includes an act 903 of determining that the I/O request pertains to an attempt to create or update a resource on the identified frozen layer. For example, layering drivers 300 can determine that I/O request 410 attempts to create app.exe on user data layer 302 c or that I/O request 510 attempts to update lib.dll on application layer 302 b.
[0061] Method 900 includes an act 904 of modifying the I/O request to direct the I/O request to the write layer such that the resource is added to the write layer rather than being added to or updated on the identified frozen layer. For example, I/O request 410 or I/O request 510 could be modified so that they are directed to the F: drive.
[0062] In summary, the present invention allows layers that are known to be safe to be treated as frozen (or read-only) layers. Any I/O that attempts to modify these layers can be redirected to a write layer where the new and/or updated resources will be isolated from the frozen layers. The resources on the write layer can then be evaluated to determine whether they are safe. If they are safe, the resources can be merged onto the appropriate frozen layers. In this way, threats that may not be detectable by common antivirus programs (e.g., zero-day attacks) can be isolated from the other resources.
[0063] Embodiments of the present invention may comprise or utilize special purpose or general-purpose computers including computer hardware, such as, for example, one or more processors and system memory. Embodiments within the scope of the present invention also include physical and other computer-readable media for carrying or storing computer-executable instructions and/or data structures. Such computer-readable media can be any available media that can be accessed by a general purpose or special purpose computer system.
[0064] Computer-readable media is categorized into two disjoint categories: computer storage media and transmission media. Computer storage media (devices) include RAM, ROM, EEPROM, CD-ROM, solid state drives (“SSDs”) (e.g., based on RAM), Flash memory, phase-change memory (“PCM”), other types of memory, other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other similarly storage medium which can be used to store desired program code means in the form of computer-executable instructions or data structures and which can be accessed by a general purpose or special purpose computer. Transmission media include signals and carrier waves.
[0065] Computer-executable instructions comprise, for example, instructions and data which, when executed by a processor, cause a general purpose computer, special purpose computer, or special purpose processing device to perform a certain function or group of functions. The computer executable instructions may be, for example, binaries, intermediate format instructions such as assembly language or P-Code, or even source code.
[0066] Those skilled in the art will appreciate that the invention may be practiced in network computing environments with many types of computer system configurations, including, personal computers, desktop computers, laptop computers, message processors, hand-held devices, multi-processor systems, microprocessor-based or programmable consumer electronics, network PCs, minicomputers, mainframe computers, mobile telephones, PDAs, tablets, pagers, routers, switches, and the like.
[0067] The invention may also be practiced in distributed system environments where local and remote computer systems, which are linked (either by hardwired data links, wireless data links, or by a combination of hardwired and wireless data links) through a network, both perform tasks. In a distributed system environment, program modules may be located in both local and remote memory storage devices. An example of a distributed system environment is a cloud of networked servers or server resources. Accordingly, the present invention can be hosted in a cloud environment.
[0068] 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. | A security solution can be implemented using a layering system. By using a layering system, any changes that are made to a computing system can be isolated within a separate write layer. Due to this isolation, the changes, which may even be malicious, can be evaluated without fear that the resources in other layers will be negatively affected. In this way, even security threats that are still unknown to antivirus solutions (so-called zero-day attacks) can be prevented from harming the system. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority under 35 U.S.C. §119 of German Patent Application No. 10 2016 007 170.2, filed Jun. 13, 2016, the disclosure of which is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a rubber tire roller for ground compaction.
BACKGROUND OF THE INVENTION
[0003] A generic rubber tire roller is known, for example, from EP 0 864 964 A2. Rubber tire rollers are ground compaction machines equipped with wheels, usually rubber wheels, with which they drive over a ground to be compacted. To this end, generic rubber tire rollers comprise a machine frame with an operating platform and front and rear undercarriages supporting the machine frame, the undercarriages respectively comprising at least one wheel. The indications “front” and “rear” relate here to the forward direction of the rubber tire roller, the rubber tire roller normally being driven over the ground alternately forward and backward during operation. The elastic properties of the wheels give rise to an advantageous rolling or kneading effect, by means of which a particular homogenous compaction of the ground surface and an advantageous closing of the pores on the ground surface can be attained. Generic rubber tire rollers are used both in earthworks and asphalt construction and are used for compacting a supporting layer of a road. The compaction effect of a rubber tire roller occurs primarily as a result of its own weight and is influenced by the same. In order to attain a wheel load required for a desired compaction performance, the rubber tire rollers need to have a high machine weight. The machine weight of the rubber tire rollers can consequently frequently be increased by attaching additional weights on the machine frame. At the same time, the machine should be configured to be as compact as possible, which has led to the machine frame of generic rubber tire rollers typically being comparatively massive or bulky.
[0004] During ground compaction, it is advantageous for the driver of the rubber tire roller to be able to observe the outer wheel edges as well as the tread of the wheels. The wheel edges are important in order to maneuver the rubber tire roller along a desired path as precisely as possible, while observing the wheel tread permits an early recognition of whether ground material is adhering to the tires, which could undesirably lead to an uneven ground surface. It is known in the prior art to equip the rubber tire rollers with mirrors and/or cameras, by means of which these areas of the wheel can be observed. Said visual supports, however, get dirty comparatively quickly, while the driver of the rubber tire roller recognizes considerably fewer details regarding the position of the wheel edges or material sticking to the wheel treads when images are conveyed by way of cameras and mirrors as is the case when the relevant areas can be viewed directly. It is also known in the prior art to use viewing tunnels through which the driver of the rubber tire roller may have a direct view of the wheels or their wheel treads. Said tunnels extend exclusively inside the machine and are, with the exception of two openings, one in the direction of the operating platform and one in the direction of the wheels, closed to the outer environment. This solution has the disadvantage that forming tunnels inside the machine frame is relatively complex, requires a lot of construction space and moreover only permits a very limited view of the wheel edges or tread of the wheels for the driver. In addition, said tunnels have to be partially illuminated in order to allow the driver to view the wheels at all.
[0005] Against this background, it is the object of the present invention to improve the viewing conditions on existing rubber tire rollers. In particular, it is the object of the present invention to allow the driver to view the relevant areas such as the wheel edges and tread of the outer wheels directly from the operating platform. The improved visibility conditions should also not result in a more complex structure of the machine, should not excessively reduce the construction space available within the machine frame and, as far as possible, should not require further components such as, e.g., lighting equipment.
SUMMARY OF THE INVENTION
[0006] Specifically, the object is achieved in a generic rubber tire roller described above in that at least one viewing indentation for the front undercarriage is formed in the machine frame, wherein the viewing indentations are configured to be laterally open over their entire extension, wherein an outer wheel edge and a wheel tread of the at least one wheel of the front undercarriage can respectively be observed by a driver of the rubber tire roller from the operating platform through the viewing indentations and wherein the viewing indentation is configured in such a way that, viewed in the forward direction, it initially widens in the horizontal plane toward the middle of the machine and then narrows away from the middle of the machine. The viewing indentation thus provides a viewing channel enabling a free field of vision from the operating platform to the at least one wheel for a driver present on the operating platform. The visible wheel edge is one of the two front-side wheel edges of the undercarriage, which are located at the outermost points on the rubber tire roller. Said wheel edges are of particular importance when the rubber tire roller has to be maneuvered along a specific path or, e.g., close to obstacles. Of relevance, here is thus one of the wheel edges of the wheel or wheels of the front undercarriage, which are located at one of both sides or the furthest away from the middle of the machine. The viewing indentation according to the present invention is formed, in particular, at least with the participation of the machine frame. In particular, it is a channel in the outer contour of the rubber tire roller or machine frame, formed by a recess or an indentation of the machine frame towards the middle of the machine, in particular with respect to the outer edge of the rubber tire roller extending in the driving direction. The viewing indentation thus constitutes an area in which the width of the rubber tire roller in the horizontal plane from the lateral outer wall or lateral outer surface transversely to the direction of travel of the rubber tire roller initially narrows from the start of the viewing indentation and subsequently widens at least towards the end of the viewing indentation. The horizontal width of the rubber tire roller transversely to the direction of travel, in particular with respect to the longitudinal middle of the machine in the direction of travel, is thus less in the area of the viewing indentation than before or after the viewing indentation in the direction of travel. This is essential for an optimal use of constructional space, as the viewing indentation does not designate a tapering off of the machine in the forward or rearward direction, but explicitly a recess that is defined and delimited both in the forward and rearward direction in the direction of travel. The viewing indentation is thus, besides being open in the viewing direction (typically upward or downward), typically open to at least one further side, in particular to the surrounding environment. The lateral opening is, in particular, transverse to the forward direction of the rubber tire roller, i.e., toward the outside or away from the middle of the machine. That the viewing indentation extends from the operating platform to the wheels does not mean in this context that the viewing indentation extends into the operating platform or the driver's cabin, but merely that it can be viewed by an operator located on the operating platform, for example, through the front windshield of the operating platform through which the operator may look into or through the viewing indentation. Thus, in contrast to the tunnel of the prior art, the viewing indentation of the present invention is open on at least three sides, in particular toward the operating platform, toward the wheels and transversely to the forward direction of the rubber tire roller away from the middle of the machine to the outside. The latter opening of the viewing indentation runs, in particular, over the entire length of the viewing indentation and opens the viewing indentation from its end on the side of the operating platform to its end on the side of the wheels completely to the longitudinally lateral surrounding environment of the rubber tire roller. This way, the viewing indentation is illuminated either by daylight or by the lighting of the construction site so that normally no additional light source is required in order to make the edges or tread of the wheels visible. By means of the viewing indentations according to the present invention, the operator of the rubber tire roller can simultaneously observe the edge as well as the tread of, e.g., the left, outer front wheel and, if a viewing indentation is also present on the opposite side of the rubber tire roller, of the right, outer front wheel. If two viewing indentations are provided for the front undercarriage, the driver can thus view the opposite top sides of the front undercarriage on the left and on the right side of the machine from the operating platform. “From the operating platform” means, in particular, that the driver of the rubber tire roller sits in the driver's seat during operation and can see or observe from this position, if necessary by leaning slightly out of the operating platform, the corresponding areas through the viewing indentations. If one imagines visual rays emanating from the driver and indicating the viewing direction of the latter, the viewing indentations according to the present invention extend along said visual rays from the operating platform up to the wheels of the rubber tire roller. Reference point for the viewing conditions through the viewing indentation in accordance with the invention is thus the height of the eyes of the operator on the operating platform, in particular of an operator in the driver's seat of the operating platform. This is determined precisely and defined by means of the so-called FPCP (“filament position centre point”) in accordance with DIN ISO 5006 “Earth-moving machinery—Operator's field of view—Test method and performance criteria”. The viewing conditions obtained via the viewing indentation in accordance with the invention thus relate to this point.
[0007] A viewing indentation on opposite sides of the rubber tire roller is preferably provided for each side of the rubber tire roller and accordingly for each of the two outer face sides of the front undercarriage. Thus, both face sides of the front undercarriage and a part of the tread of the outer wheels of the front undercarriage are visible from the operating platform. The two viewing indentations for the front undercarriage are, in particular, configured to be identical with one another in this case, said indentations being mirrored on a vertical plane running parallel to the machine frame. The formation of the viewing indentations according to the present invention as embrasures or channels or recesses formed in the machine frame allows a particularly simple configuration of the machine frame without additional constructional elements, by which means manufacturing costs for the rubber tire roller according to the present invention are kept low.
[0008] As a result of the special viewing conditions obtained by means of the viewing indentation in accordance with the invention, maneuvering of the rubber tire roller during operation is substantially improved, as the driver is able to view at least one and, in particular, both (in the case of two viewing indentations) outer wheels of the undercarriage, viewed transversely to the forward direction, or their face sides extending in the forward direction. Here it is preferred if the viewing indentation extends from the outer side in the horizontal plane far enough toward the middle of the machine that the driver can view at least a third, in particular at least the half and especially the complete width of the rubber tire in question from the FPCP. Additionally, or alternatively, the viewing indentation is further preferably configured in such a way that the driver, especially from the FPCP, views the external surface of the rubber tire and/or at least partially the area above the vertical center of the outer tire surface in a virtual, vertical reference plane from above. This way, besides having an improved view of the side edges, the driver can recognize particularly quickly if there is, e.g., material adhering to the treads of the rubber tires and accordingly adjust e.g. suitable process parameters (separation agent mixture, spraying device, driving speed, etc.). The viewing indentations thus contribute significantly to an improvement of the process.
[0009] However, an even more precise control of the path of the rubber tire roller can be attained when at least one further viewing indentation is provided, through which at least one of the outer wheels of the rear undercarriage can be viewed. It is thus preferred to have a third viewing indentation for the rear undercarriage configured in the machine frame, wherein the third viewing indentation allows a continuous, unobstructed view from the operating platform to the rear wheels and is preferably configured to be open to one side over its entire extension, wherein an outer wheel edge and a wheel tread of the at least one wheel of the rear undercarriage can be viewed by a driver of the rubber tire roller through the third viewing indentation. The configuration of the third indentation corresponds to the configuration of the viewing indentations for the front undercarriage described above. Through the third viewing indentation, the driver can observe one of the outer rear wheels, in particular its edge and tread, and control the motion of the rubber tire roller at the rear wheel as well. According to a further embodiment of the present invention, a total of four viewing indentations are provided, two for the front undercarriage and two for the rear undercarriage, and the driver is able to view all edges and treads of the outer wheels, both at the front and in the rear as well as left and right on the rubber tire roller. In particular, the viewing indentations for the front and rear undercarriages are respectively identical and their configurations mirror each other. As a result of the extended visibility, the rubber tire roller can be controlled by the operator particularly advantageously and simply. Whenever the term “viewing indentations” is used in the following, it refers to the at least one viewing indentation or to the viewing indentations present on the rubber tire roller in question.
[0010] In principle, it would be best for the visibility of the wheels to reduce the machine frame of the rubber tire roller to a skeleton carrier frame and thus provide the driver with an unobstructed view of all wheels. However, as already described above, the machine frame of the rubber tire roller not only serves to increase the machine weight as far as possible in order to set the wheel load for a desired ground compaction performance, but rather the machine frame carries further essential components, such as the power unit or a water tank for wetting the tread of the wheels, the latter defining the size and shape of the machine frame in question by means of their dimensions. Ultimately, a compromise must be found between the visibility of the wheels through the viewing indentations and the necessary size of the machine frame. In other words, the machine frame cannot be reduced toward the middle of the machine to an arbitrary extent in order to create a viewing indentation for the driver. Preferably, the viewing indentations provided are formed in such a way that the machine frame is only reduced toward the middle of the machine in sections and protrudes laterally outward beyond the viewing indentations in the remaining areas of the outer contour of the rubber tire roller. The machine frame thus forms all side walls of the viewing indentations and limits them. In particular, it is preferred for at least one viewing indentation to be limited in the forward direction to the front and/or to the rear by side walls formed by the machine frame. This allows the driver to have an unobstructed view of the relevant wheels of the rubber tire roller through the viewing indentations, and sufficient space is provided within the machine frame for the components of the rubber tire roller housed therein. In particular, components of the rubber tire roller can be housed in the machine frame in the regions protruding beyond the viewing indentations transversely with respect to the forward direction, in particular tanks, by which means less construction space is lost according to the present invention. For example, the viewing indentations are configured as channels formed in the machine frame and thus in the outer contour of the rubber tire roller, by which means the loss in construction space within the machine frame is exactly as large as necessary in order to provide the driver with an efficient viewing channel.
[0011] In principle, the side walls of the viewing indentation formed by the machine frame may extend in varying manners in relation to one another, e.g., obliquely. However, it has proven particularly advantageous for the visibility conditions through the viewing indentation if the front and rear side walls—viewed in the forward direction—of the viewing indentation formed by the machine frame run parallel to one another. In particular, this means that the viewing indentation has a constant diameter in the viewing direction of the driver, i.e., in the direction from the operating platform to the different wheels. This ensures an unobstructed view of the wheels for the driver from the operating platform.
[0012] Ideally, the viewing indentation is configured in such a way that the ground area lying in front of the rubber tire roller beyond the tread of a tire can be viewed by an operator on the operating platform through the viewing indentation. For the definition of the required viewing beam of the operator on the operating platform, reference is made here in particular to the so-called FPCP (filament position center point) in accordance with ISO 5006:2017. This document norms a viewing starting point for an operator sitting in a driver's seat on the operating platform. In this preferred embodiment, the driver can thus look through the viewing indentation over at least a part of the tire tread obliquely downward and thus see a ground area lying essentially directly in front of or at least very close to the front of the rubber tire roller. This is, in particular, advantageous when the driver would like to drive close to an obstacle, e.g., a paving screed of a road paver. The viewing indentation extends in the forward direction far enough that a viewing channel from the FPCP is created, stretching from the FPCP through the viewing indentation past the rubber tire roller, ideally over the tread of the rubber tire, to the ground area lying in front of the rubber tire roller in the direction of travel.
[0013] Several devices of the rubber tire roller are arranged on the machine frame, in particular on the front end of the machine frame in the forward direction, such as headlamps, rearview mirrors, etc. It is thus preferred, in particular for the at least one viewing indentation for the front undercarriage, if the viewing indentation is limited at the front and at the rear, viewed in the forward direction, by side walls formed by the machine frame so that the machine frame protrudes beyond said viewing indentation in the front and rear, viewed in the forward direction, thus making construction space available for further devices, for example, as a mount for headlamps and/or mirrors. In contrast, it has proven sufficient in the rear, i.e., at the back of the rubber tire roller, viewed in the forward direction, if the viewing indentation for the rear undercarriage is delimited in the forward direction to the front by a side wall formed by the machine frame and open to the rear. In other words, the viewing indentation for the rear undercarriage is a narrowing of the machine frame that continues to the rear of the rubber tire roller. Accordingly, the machine frame of the rubber tire roller does not protrude behind the viewing indentation for the rear undercarriage, but rather ends in a plane with the inner wall of the viewing indentation, recessed toward the machine center. The viewing indentation for the rear undercarriage is thus configured in a particularly generous manner so that the driver of the rubber tire roller is able to view the edge and tread of the outer rear wheel particularly well.
[0014] In principle, the viewing indentations could reveal any place on the wheels where the wheel edges and tread surfaces are visible, for example, in the area of the tread surfaces located in the rear when viewed in the forward direction. A tracking of the steering angle and thus an improved control of the steering of the corresponding rubber tire roller is particularly successful if the vertical upper side of the tread of the wheels, i.e., the side facing away from the ground in during operation, can be viewed by an operator from the operating platform. In order to ensure this, it is preferred for the viewing indentations to extend through the machine frame also vertically above the wheels. The viewing indentations thus end, for example, in the wheel housing in the area above a wheel facing away from the ground during operation of the rubber tire roller. The upper surfaces of the wheels, i.e., their tread surfaces and their outer edges running transversely to the forward direction, can be viewed best from this point.
[0015] Usually, rubber tire rollers or their machine frames comprise a hood in front of and/or behind the operating platform in the forward direction, e.g., an engine hood and/or a tank, for example, a water tank. These hoods can be opened up or pivoted so that access to components arranged within the machine frame of the rubber tire roller, for example, for maintenance work, is provided. If the machine frame comprises a hood in front of and/or behind the operating platform in the forward direction, it is preferred for the viewing indentations to extend through the hood. The contour of the viewing indentations or the viewing indentations per se are thus not only formed by the machine frame itself, but also by the hoods arranged on the machine frame, i.e., their contour is continued by a corresponding design of the hoods. All lateral surfaces and inner surfaces of the viewing indentations formed by the machine frame thus also continue in the hood or hoods. As a result, the present invention can also be realized with rubber tire rollers having such hoods. Additionally, or alternatively, a corresponding configuration of further elements, for example, tanks, is also possible.
[0016] A further option for providing sufficient construction space on the machine frame despite the viewing indentations according to the present invention consists in configuring the front and/or rear side walls, when viewed in the forward direction, of the respective viewing indentations formed by the machine frame, to be undercut. By means of the undercut, the width of the viewing indentation narrows outwards, the undercut in accordance with the present invention never effecting a complete closure of the viewing indentation to the side. In other words, the viewing indentation is configured in such a way that it enlarges or widens from the vertical plane of the outer contour of the rubber tire roller towards the middle of the machine. In this preferred embodiment, at least one viewing indentation, in particular both viewing indentations for the front undercarriage, undercuts the machine frame in such a way that the viewing indentation is partially configured to be limited to one side by the machine frame. This undercut describes the viewing indentation and, in particular, the part of the viewing indentation covered or limited to the outside by an overhang of the machine frame. Such an undercut can be configured by an oblique side wall or by an additional element arranged to the outer side of the viewing indentation, for example, a piece of sheet metal.
[0017] In modern rubber tire rollers, the undercarriages typically comprise several wheels spaced apart from one another transversely in the forward direction, the wheels of the front undercarriage being arranged transversely to the forward direction in an offset manner relative to the wheels of the rear undercarriage in the gaps of the latter. In other words, the wheels of the undercarriages are arranged in an offset manner transversely to the forward direction so that the ground of the roller's path is essentially passed over by one wheel only when the rubber tire roller drives over it, although naturally a certain path overlap is envisaged in order to achieve a homogenous compaction. If the rotational axes of the front and rear undercarriages are projected over one another, there is an alternating overlap of a front and a rear wheel, i.e., the front wheels lie essentially in a gap between two rear wheels and vice versa. Such an arrangement of the wheels of the front and rear undercarriages automatically results in one wheel of the rear undercarriage projecting further outwards on one side of the rubber tire roller transversely to the forward direction than the wheels of the front undercarriage and vice versa. It is thus preferred for the viewing indentation for the rear undercarriage to be directed to this wheel edge, i.e., the wheel edge offset to the outside in relation to the front wheel edge. In other words, the viewing indentation for the rear undercarriage should be arranged specifically on the longitudinal side of the rubber tire roller on which the outermost wheel edge of the rear undercarriage, viewed transversely to the forward direction, protrudes beyond the outermost wheel edge of the front undercarriage. As this wheel edge of the rear undercarriage defines an outer edge of the path of the entire rubber tire roller, it is of particular importance during operation, in particular for steering the rubber tire roller exactly along a predetermined path. It is thus advantageous if, in addition to the edges of the outer wheels of the front undercarriage arranged transversely to the forward direction, the edge of this wheel can also be viewed from the operating platform during operation.
[0018] The operating platform itself should also be configured so as to permit the driver an unobstructed view through the viewing indentations. For the most part, operating platforms of rubber tire rollers are equipped with a cabin comprising a roof. In such rubber tire rollers, the operating platform comprises support bars which support the roof. These bars essentially rise upwards and are made of a non-transparent material, usually steel. In order to provide the driver with an unobstructed view through the viewing indentations despite said support bars, it is preferred for the support bars, at least in the driver's field of vision, to be arranged toward the middle of the machine transversely to the forward direction relative to the viewing indentations so that the viewing indentations can be viewed in an unobstructed manner from the operating platform by the driver of the rubber tire roller. In principle, it would also be possible for the support bars to be arranged transversely to the forward direction to the outside so that an unobstructed view through the viewing indentations is obtained. However, it is preferred in accordance with the present invention that the support bars are arranged toward the middle of the machine, i.e., away from the outer edge of the rubber tire roller, in particular towards the center. This way, firstly, a secure mounting of the driver's cabin or of the roof of the driver's cabin can be attained, while it is simultaneously ensured that the support bars do not obstruct the view of the driver from the operating platform or from the driver's seat through the viewing indentations.
[0019] Rubber tire rollers comprise various devices that have to be reached by an operator, e.g., for maintenance purposes on their vertically upward side, i.e., their top side or side facing away from the ground to be compacted during operation. For the most part, rubber tire rollers comprise a water tank in which water is carried for wetting the rubber tires. The cover for this tank is often located on the top side of the rubber tire roller. These devices on the vertically upward side of the rubber tire roller are often arranged relatively high up and are thus hard to access. The present invention now permits a simplified operation of the rubber tire roller during maintenance work. For this purpose, in one embodiment of the present invention, at least one viewing indentation, in particular a viewing indentation for the front undercarriage, is configured to be open at the top. The viewing indentation is thus, at least partially, not limited upwards by the machine frame or other projecting parts of the rubber tire roller. In other words, a part of the viewing indentation forms a notch that is open at the top or a recess in the machine frame. This notch or recess is located, in particular, in an area in which a device that has to be reached by an operator from time to time is arranged on the vertically upper side. As a result of the notch according to the present invention, it is easier for the operator to reach this device, as it is possible to lean, for example, with the torso, into the notch, by which means it is possible to reach the top of the machine frame. This way, the machine operator can reach points closer to the middle of the machine center than in conventional forms of the machine frame. An operator standing next to the rubber tire roller can also reach devices on the rubber tire roller that are arranged high up.
[0020] This effect can be further enhanced by providing a step for an operator, in particular in the region of the viewing indentation configured to be open at the top. The step denotes, in particular, a platform or foothold on which the operator can place at least one foot or even two feet. In this case, the step is arranged at a certain distance from the ground on the machine frame so that the operator can reach the devices arranged vertically high up on the rubber tire roller a lot easier by climbing on the step. The step is particularly helpful wherever the viewing indentation configured to be open at the top is located. Together with the viewing indentation open at the top, the step makes it considerably easier to reach the devices of the rubber tire roller that are arranged high up.
[0021] Reaching devices arranged higher up on the rubber tire roller can be made still easier in a further embodiment by configuring a step recess in the machine frame in addition to the viewing indentation, in particular vertically above the step, said step recess preferably being configured in the viewing indentation. The step recess is also configured as an indentation in the machine frame and preferably extends from the vertically lower end of the rubber tire roller or from the step over the entire height of the rubber tire roller vertically upward. This embodiment can be realized in a particularly advantageous manner if the step recess, in particular in the vertically top region of the rubber tire roller, is combined with the viewing indentation, by which means a certain area of the viewing indentation or step recess is used both as a step for an operator as well as for the driver's view of the wheels. As a result of this dual use of one and the same indentation in the machine frame, the construction space for the machine frame is only limited once and thus less than it would be if both indentations were formed separately in the machine frame. The step recess is configured in such a way that an operator either standing next to the rubber tire roller or on the step can enter the step recess and thus reach over the outer contour of the machine toward the middle of the machine. This way, it is considerably easier for the operator of the rubber tire roller to reach devices that are hard to reach, e.g., which are arranged vertically high up, than would be the case if he or she were merely standing next to the rubber tire roller, in particular outside the outer contour of the same. A particularly advantageous accessibility of these devices is attained by combining a viewing indentation that is vertically open at the top with a step recess in a particularly advantageous embodiment of the present invention. This renders handling of the rubber tire roller considerably easier, in particular during maintenance works.
[0022] Preferably, an access cover, in particular for an operating fluid tank or a ballast tank, is arranged in the at least one viewing indentation for the front undercarriage. This arrangement is, firstly, easy to reach from outside the rubber tire roller and, secondly, has the advantage that is does not protrude beyond the outer side of the machine. Typical operating fluids can be water, oil or other operating fluids, for example. Alternatively, or additionally, the arrangement of an access to a ballast device at this location is particularly advantageous. This can be a ballast space for sand or other ballast materials. Preferably, it is a ballast tank for water.
[0023] In order to be able to use them on construction sites in confined conditions as well, rubber tire rollers are often suspended by means of a crane and moved by the latter. In order to permit such a suspension, fastening means must be provided on the rubber tire roller for the crane. In order to permit a balanced suspension, the fastening means for the crane typically have to be arranged in the regions of the rubber tire roller in which the viewing indentations are arranged in accordance with the present invention. It is thus necessary, firstly, to provide suitable fastening means and, secondly, not to restrict the view of the operator of the rubber tire roller through the viewing indentations as a result of the fastening means. It is thus preferred to have transport loops arranged in the side walls of the viewing indentations formed by the machine frame for suspending the rubber tire roller. For reasons of balance, it is also advantageous if the transport loops are configured to be as far away as possible from the middle of the machine, i.e., on the outer contour of the rubber tire roller. The transport loops are thus preferably arranged at the junction of the side walls of the viewing indentations and the outer contour of the rubber tire roller. In particular, the transport loops are configured as an integral part of the machine frame.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] In the following, the present invention is described in greater detail by means of the illustrative embodiments shown in the figures, which show schematically:
[0025] FIG. 1 is a side view of the rubber tire roller;
[0026] FIG. 2 is a top view on the rubber tire roller shown in FIG. 1 ;
[0027] FIG. 3 is the offset between the front and rear undercarriages of the rubber tire roller;
[0028] FIG. 4 is a side view of a viewing indentation for the front undercarriage;
[0029] FIG. 5 is a top view of a viewing indentation for the front undercarriage;
[0030] FIG. 6 is a side view of a viewing indentation for the rear undercarriage;
[0031] FIG. 7 is a top view of a viewing indentation for the rear undercarriage;
[0032] FIG. 8 is a perspective view of the rubber tire roller from the front left;
[0033] FIG. 9 is a perspective view of the rubber tire roller from the front right;
[0034] FIG. 10 is a front view of the rubber tire roller obliquely from the top; and
[0035] FIG. 11 is a rear view of the rubber tire roller obliquely from the top.
[0036] Components that are identical or have identical functions are designated with the same reference numbers. Repetitive components are not necessarily indicated separately in each figure.
DETAILED DESCRIPTION OF THE INVENTION
[0037] FIGS. 1 to 11 show a preferred illustrative embodiment of a rubber tire roller 1 according to the present invention. Generally, rubber tire rollers 1 comprise an operating platform 2 and a machine frame 3 . During operation, the rubber tire rollers 1 are driven by a power source 4 , mostly a diesel engine, and move alternately in the forward direction a or contrary to the forward direction a over the ground 8 by means of a driven front undercarriage 5 and a rear undercarriage 6 . The undercarriages 5 and 6 respectively comprise four individual wheels arranged next to one another. Ideally, a driver's seat that is displaceable over the width of the platform is arranged on the operating platform 2 . In FIG. 1 , an approximate position of the FPCP in accordance with DIN ISO 5006:2017 is indicated for illustrative purposes.
[0038] In order to render the steering of the machine easier for the driver of the rubber tire roller 1 , the embodiment of the rubber tire roller 1 shown comprises two viewing indentations 11 for the front undercarriage 5 . More specifically, the machine frame 3 of the rubber tire roller 1 comprises a viewing indentation 11 through which, from the operating platform 2 of the rubber tire roller 1 , the driver can view the wheel 9 located on the outer right, in particular its wheel edge A transverse to the forward direction a and tread. Moreover, the machine frame 3 of the rubber tire roller 1 comprises a further viewing indentation 11 , through which the outer wheel arranged on the front left of the front undercarriage 5 can be viewed from the operating platform 2 . Here as well, the outer wheel edge B located on the front left and the tread of the outer wheel 9 on the front left are visible for the driver from the operating platform 2 . As can be seen, in particular, in FIG. 2 , the viewing indentations 11 for the front undercarriage 5 are located on the opposite longitudinal sides of the machine frame 3 of the rubber tire roller 1 and essentially at the same position in the longitudinal direction or forward direction a of the rubber tire roller 1 .
[0039] Furthermore, the rubber tire roller 1 comprises a third viewing indentation 18 for the rear undercarriage 6 . Through the viewing indentation 18 , the tread and the wheel edge C of the left outer rear wheel 10 is visible for the driver. The wheel edges A, B, C are thus the wheel edges located farthest away from the middle of the machine of the rubber tire roller 1 in a direction transverse to the forward direction a. As the driver of the rubber tire roller 1 is able to view these wheel edges A, B, C during operation, the rubber tire roller 1 can be steered particularly easily. Furthermore, the tread of the respective wheels 9 , 10 can also be viewed via the viewing indentations 11 , 18 so that the driver of rubber tire roller 1 can determine if ground material, in particular, e.g., asphalt, is adhering to the tread of the wheels 9 , 10 . In case material is actually sticking to the wheel tread, stripping devices 7 are provided, which can at least partially remove the adhering material from the wheel tread.
[0040] As a result, a total of three outer wheel edges A, B, C, and in part the corresponding wheel treads, can be viewed by the driver from the operating platform 2 by means of the exactly three viewing indentations 11 , 18 . The selection of the three wheel edges A, B, C from all four theoretically selectable wheel edges is described in further detail by means of FIG. 3 . FIG. 3 schematically shows the positions of the front wheels 9 of the front undercarriage 5 relative to the rear wheels 10 of the rear undercarriage 6 in a top view. In the illustrative embodiment shown, the front undercarriage 5 comprises four front wheels 9 and the rear undercarriage 6 comprises four rear wheels 10 . The front wheels 9 and the rear wheels 10 are respectively spaced apart from one another transversely to the forward direction a. The front wheels 9 are arranged in the gaps in relation to the rear wheels 10 transversely to the forward direction a. This means that the front wheels 9 are arranged at an offset transversely to the forward direction a with respect to the rear wheels 10 in such a way that the paths of the individual wheels respectively only overlap at their edges and that the a portion of the ground 8 , when passed over once by the rubber tire roller 1 , is essentially driven over by one wheel 9 , 10 only, belonging either to the front undercarriage 5 or to the rear undercarriage 6 . As the rubber tire roller 1 is typically steered by means of the front undercarriage 5 , the wheel edges A, B arranged on the outside and transversely to the forward direction a are of particular importance for a precise control and steering of the rubber tire roller 1 . Moreover, the wheel edge C of the left rear wheel 10 protrudes further outward transversely to the forward direction a than the wheel edge B of the outer left front wheel 9 as a result of the offset of the rear wheels 10 in relation to the front wheels 9 transversely to the forward direction a. The wheel edge C of the wheel 10 is thus located the farthest outwards on the rear undercarriage 6 transversely to the forward direction a and thus marks the outer limit of the overall path of the rubber tire roller 1 at the rear on the left. The wheel edge C of the rear undercarriage 6 is thus also of particular importance for steering the rubber tire roller 1 , in particular for maneuvering the rubber tire roller 1 along a predefined path and/or along obstacles. The fourth wheel edge at the rear on the right, in contrast, is offset transversely to the forward direction a towards the middle of the machine in relation to the front outer right wheel edge A and thus automatically always lies within the overall path of the rubber tire roller 1 . This wheel edge is thus less important for maneuvering or steering the rubber tire roller 1 and does not necessarily need to be viewable through a viewing indentation. The preferred embodiments of the present invention are thus limited to exactly three viewing indentations 11 , 18 , through which the specific wheel edges A, B, C are visible.
[0041] FIGS. 4 and 5 show a detailed illustration of a viewing indentation 11 for the front undercarriage 5 in accordance with the boxes IV and V indicated in FIGS. 1 and 2 . The second viewing indentation 11 , located at the front on the right in the forward direction a, is configured to be essentially identical to the viewing indentation 11 shown so that the indications given below also apply to the second viewing indentation 11 located at the front on the right on the rubber tire roller 1 in the forward direction a. FIG. 4 shows a side view of the viewing indentation 11 , while FIG. 5 shows a top view. The viewing indentation 11 is formed by the machine frame 3 . In particular, the viewing indentation 11 is formed as a recess in the machine frame 3 . It extends continuously from the wheels 9 to the operating platform 2 . The viewing indentation 11 ends vertically above the wheels 9 , in particular in the wheel house of the wheels 9 . The formulation that the viewing indentation 11 “runs continuously to the operating platform 2 ” means that there is no obstacle to impede a driver's view of the wheels 9 from the operating platform 2 (FPCP) through the viewing indentation 11 in a virtual extension of the viewing indentation 11 towards the operating platform 2 , in particular along the viewing direction of a driver located on the operating platform 2 . The viewing indentation 11 thus forms a free space between the operating platform 2 and the wheels 9 , through which the driver can see the wheels 9 from the operating platform 2 . The operating platform 2 does not have to be open in extension of the viewing indentation 11 , but rather it is sufficient that the driver can look through the viewing indentation 11 from the operating platform 2 , e.g., through a window or a front or rear windshield of the of the operating platform 2 . The viewing indentation comprises a front lateral wall 22 located in the forward direction a in the front and a rear lateral wall 23 located in forward direction a in the rear. Moreover, the viewing indentation 11 is delimited by an inner wall 25 toward the middle of the machine, i.e., transversely to the forward direction a. Opposite the inner wall 25 , the viewing indentation 11 is open towards the outer environment, in particular over its entire length. The front side wall 22 , the rear side wall 23 and the inner wall 25 are respectively formed by or are a part of the machine frame 3 . The front side wall 22 and the rear side wall 23 run in the direction of or parallel to the driver's viewing direction from the operating platform 2 when the latter, sitting, e.g., in the driver's seat, looks toward the wheels 9 , which can be viewed through the viewing indentation 11 . In particular, the front lateral wall 22 and the rear lateral wall 23 also extend parallel to one another, as shown in FIG. 4 .
[0042] As shown in FIG. 5 , the side walls 22 , 23 of the viewing indentation 11 extend from a machine frame outer edge 21 to a machine frame inner edge 24 formed by the inner wall 25 . The machine frame inner edge 24 and the machine frame outer edge 21 essentially extend parallel to the forward direction a as well as parallel to one another. The machine frame outer edge 21 constitutes the edge of the machine frame 3 located the furthest outwards, i.e., transversely to the forward direction a. In other words, the machine frame outer edge 21 of the machine frame 3 is located the furthest away from the center of the machine, in particular transversely to the forward direction a. The distance between the machine frame outer edge 21 and the machine frame inner edge 24 is the depth of viewing indentation 11 . The depth of viewing indentation 11 is essentially defined by the extension of the side walls 22 , 23 transverse to the forward direction a. The front side wall 22 and the rear side wall 23 can essentially extend in a direction transverse to the forward direction a. As indicated in FIGS. 4 and 5 , the rear side wall 23 extends along the viewing direction of the driver and essentially transversely to the forward direction a. The front side wall 22 , in contrast, extends not only transversely to the forward direction a, as is evident, in particular, in FIG. 5 , but also toward the middle of the machine center and in the forward direction a. Side walls 22 , 23 run from the machine frame outer edge 21 to the machine frame inner edge 24 , which is essentially formed by the inner wall 25 . As is evident from FIG. 5 , the front side wall 22 extends obliquely between the machine frame outer edge 21 and the machine frame inner edge 24 in such a way that the viewing indentation is configured to widen from the machine frame outer edge 21 toward the machine frame inner edge 24 or from the outer side of the rubber tire roller 1 toward the middle of the machine. As a result of the extension of the front side wall 22 transverse to the forward direction a and in the forward direction a, an overhang of the machine frame 3 occurs in the area of the viewing indentation 11 , the overhang being configured in such a way that the viewing indentation 11 is also at least partially limited by the machine frame 3 transversely to the forward direction and away from the center of the machine. In other words, the limitation is arranged in the region opposite the inner wall 25 . However, it should be noted that this limitation does not close the opening of the viewing indentation 11 opposite the inner wall 25 toward the external environment. As a result of this special arrangement of the machine frame 3 in the region of the viewing indentation 11 , construction space is saved while a visually appealing design of the viewing indentation 11 is attained.
[0043] It is thus important that the width B of the rubber tire roller in a virtual horizontal reference plane transverse to the direction of travel a is smaller in the area of the viewing indentation 11 (width B 1 ) than it is before (width B 2 ) or after (width B 3 ) the viewing indentation 11 in the direction of travel. The viewing indentation thus does not constitute a tapering off of the machine in the forward or rearward direction, as is the case, e.g., with the lateral recess 18 described below in greater detail. Rather, the viewing indentation 11 has a front and a rear delimiting wall in the direction of travel, which extend at least obliquely in relation to the direction of travel. The machine is thus narrower with respect to its horizontal width, when viewed in the direction of travel, over the viewing indentation 11 in relation to the starting width before the area of the viewing indentation, and subsequently broader, in the present case as wide as before the indentation.
[0044] In this context, FIG. 2 makes it clear that the viewing indentation recesses from a maximal outer side wall extension far enough toward the middle of the machine that more than half and in particular more than two-thirds of the tread width of the rubber tire on the outer, right-hand side is visible.
[0045] FIGS. 6 and 7 show a side view and a top view of the viewing indentation 18 of rubber tire rollers 1 in accordance with the boxes VI and VII shown in FIGS. 1 and 2 . The statements regarding the viewing indentation 11 in accordance with FIGS. 4 and 5 also apply to the viewing indentation 18 so that below mainly the differences between viewing indentation 18 and viewing indentation 11 are elucidated. The viewing indentation 18 , like the viewing indentation 11 , is located between a machine frame outer edge 21 and a machine frame inner edge 24 . The viewing indentation 18 for the rear undercarriage 6 also comprises an inner wall 25 and a front lateral wall 22 , both of which being formed by the machine frame 3 . In contrast to the viewing indentation 11 , the viewing indentation 18 does not have a rear side wall 23 , but rather is configured to be open to the rear vis-à-vis the forward direction a. This means that the rear of the machine frame 3 , in relation to the forward direction a, ends, in particular, in the upper region at the level of the machine frame inner edge 24 . The front side wall 22 of viewing indentation 18 extends from the machine frame outer edge 21 to the machine frame inner edge 24 , in particular in such a way that the front side wall 22 of the machine frame outer edge 21 extends transversely to the forward direction a and opposite the forward direction a to the machine frame inner edge 21 . This way, there is no overhang of the machine frame 3 at the viewing indentation 18 , while construction space is nevertheless saved. As is evident, in particular, from FIG. 1 , the front side wall 22 has the same angle in the vertical plane as the rear side wall 23 and the front side wall 22 of the viewing indentations 11 for the front undercarriage 5 . In particular, the values of the respective angles of the side walls 22 , 23 in relation to a vertical plane correspond, while the extension of the side walls 22 , 23 of the front viewing indentations 11 and thus also their angles relative to a vertical plane, mirror the extension and the angle in the vertical plane of the rear viewing indentation 18 .
[0046] The machine frame 3 of the rubber tire roller 1 includes a front hood 19 in the forward direction a and a rear hood 20 in the forward direction a. The front hood 19 and the rear hood 20 are configured, e.g., as pivotable hoods 19 , 20 , which can be swiveled about a pivot axis in order to render devices mounted in the machine frame accessible for maintenance purposes. As is evident, in particular, from FIG. 2 and FIGS. 10 and 11 , the viewing indentations 11 , 18 continue into the hoods 19 , 20 . In particular, the machine frame 3 or its hoods 19 , 20 of the rubber tire rollers 1 are configured in such a way that the front side wall 22 , the rear side wall 23 and the inner wall 25 of the viewing indentations 11 , 18 continue into the hoods 19 , 20 without causing a change in the cross section or cross-sectional profile of the viewing indentations 11 , 18 in the driver's viewing direction. The hoods 19 , 20 are thus also configured to permit an operator to have unobstructed view of the wheels 9 , 10 or the wheel edges A, B and C and tread surfaces through the viewing indentations 11 , 18 from the operating platform 2 of the rubber tire roller 1 .
[0047] In particular FIG. 11 , in which the top view of the machine is tilted in such a manner that the viewing beam of the operator in the driver's seat or from the FPCP extends at a very steep angle in relation to the plane of the picture, makes it clear that a viewing of the ground B beyond the rubber tire in question is possible through the viewing indentation from the FPCP. As a result, the driver can view in particular the area lying directly in front of the rubber tire roller from the driver's seat, which makes, e.g., maneuvering easier.
[0048] It is evident from FIGS. 1, 2, 8 and 9 that the rubber tire rollers 1 comprise a roof 27 for their operating platforms 2 . The roof 27 is supported by support bars 17 , which connect the roof 27 to the machine frame 3 . In order to improve the driver's view from the operating platform 2 through the viewing indentations 11 , 18 , in particular through the viewing indentation 18 , e.g., the support bar 17 located on the side of the viewing indentation 18 of the rubber tire roller 1 , i.e., in the rear on the left, is arranged closer to the middle of the machine. Instead of arranging the support bar 17 essentially on the machine frame outer edge 21 , as it is common in the prior art, the corresponding support bar is thus arranged away from the machine frame outer edge 21 towards the middle of the machine, transversely to the forward direction a, by the distance 26 . The distance 26 between the machine frame outer edge 21 and the position of the support bar 17 is selected so that the operator is able to view the rear wheel 10 or the wheel edge C of the rear wheel 10 of the rear undercarriage through the viewing indentation 18 from the operating platform 2 or a position on the driver's seat. Such an offset of the support bar 17 of the roof 27 is, in particular, suitable at the rear of the operating platform 2 in relation to the forward direction a, as it needs to be ensured that the driver's view to the front through the windshield 2 in the forward direction a is as unobstructed as possible. In case the driver would like to view the left rear wheel 10 from the operating platform 2 , he or she turns naturally to the left or takes a look over his or her left shoulder so that moving the support bar 17 on this side from the machine frame outer edge 21 to the middle of the machine by the distance 26 ensures an unobstructed view through the viewing indentation 18 .
[0049] It is further evident from FIGS. 2, 8 and 10 that a cover 14 is arranged in at least one of the viewing indentations. In the present embodiment, access to a space for ballast, in particular a ballast tank for water, is possible via said cover 14 . Its placement within the viewing indentation 11 , firstly, saves space and, secondly, permits a ready access from outside the rubber tire roller 1 , for example, in order to fill the ballast tank.
[0050] As is evident from FIG. 2 , for example, the viewing indentations 11 , 18 are configured to be open at the top, i.e., on the side facing away from the ground. This means that the machine frame 3 of the rubber tire rollers 1 recedes towards the machine frame in the region of the viewing indentations 11 , 18 at its upper edge, which would not be the case without the formation of the viewing indentations 11 , 18 . This way, it is easier for an operator to reach devices arranged on the top side of the rubber tire roller 1 or on one of the hoods 19 , 20 , such as, e.g., a water tank lid 13 , as the operator may lean against the rubber tire roller 1 and get closer to the middle of the machine of the rubber tire roller 1 by means of the viewing indentations 11 , 18 configured to be open at the top. This way, smaller operators can also easily reach devices arranged higher up on the rubber tire roller 1 . This is achieved particularly advantageously, e.g., in the embodiment of a rubber tire roller 1 according to FIG. 9 . In this case, a step 12 is arranged at the front right viewing indentation 11 , said step 12 lying vertically below the viewing indentation 11 . The step 12 here is configured as a foothold or platform on which the operator can stand if he or she wishes to access devices in the upper area of the rubber tire roller 1 . This is rendered even simpler by the step recess 16 shown in FIG. 9 , which is also formed by the machine frame 3 and which extends substantially vertically upwards from the step 12 , i.e., away from the ground 8 and, in the embodiment shown, also in the direction of the viewing indentation 11 . The step recess 16 is arranged at a viewing indentation 11 , 18 and, in particular, vertically below the viewing indentation 18 , 19 . The step recess 16 merges with the viewing indentation 11 , which is configured to be open at the top. This way, a continuous recess is created in the machine frame 3 , extending vertically upwards or away from the ground and in part through the step recess 16 and in part through the viewing indentation 11 . An operator may now climb or move into said recess by placing himself/herself on the step 12 . As a result of the combined recess, the operator can get much closer to the middle of the machine and thus reaches devices located high up or closer to the middle of the machine of the rubber tire roller 1 , which otherwise would have been hard to access, considerably easier.
[0051] The rubber tire rollers 1 of the present invention further comprise transport loops 15 for the suspension of the rubber tire roller 1 , said transport loops 15 being configured so as to attach transport means to the rubber tire roller 1 . This way, the rubber tire roller 1 can be lifted, e.g., by a crane and placed somewhere else when the rubber tire roller 1 is connected to a corresponding suspension means of the crane via the transport loops 15 . According to the present invention, the transport loops 15 are formed by the machine frame and are, in particular, arranged in the region of the viewing indentations 11 , 18 . Preferably, the transport loops extend parallel to the machine frame outer edge 21 or lie in a plane with the machine frame outer edge 21 . This way, the rubber tire roller 1 can be balanced particularly easily by means of the suspension on the transport loops 15 , while this does not result in an obstructed view through the viewing indentations 11 , 18 for the driver. In the illustrative embodiments shown in the figures, each viewing indentation 11 , 18 comprises a corresponding transport loop 15 .
[0052] While the present invention has been illustrated by description of various embodiments and while those embodiments have been described in considerable detail, it is not the intention of Applicants to restrict or in any way limit the scope of the appended claims to such details. Additional advantages and modifications will readily appear to those skilled in the art. The present invention in its broader aspects is therefore not limited to the specific details and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of Applicants' invention. | The present invention relates to a rubber tire roller for ground compaction, comprising a machine frame and an operating platform and front and rear undercarriages supporting the machine frame, wherein the undercarriages each comprise at least one wheel. A fundamental idea of the present invention lies in viewing indentations that are open to the side. | 4 |
RELATED APPLICATIONS
[0001] This is a continuation application of International Application PCT/EP2006/050530, filed Jan. 30, 2006, which claims priority to DE 10 2005 005 017.4, filed Feb. 3, 2005, which are hereby incorporated by reference in their entirety.
BACKGROUND
[0002] Monitoring blood glucose concentration is an essential part of the daily routine for diabetics. Blood glucose concentration must be determined rapidly and with ease several times daily in order to take appropriate medical measurements. In order to not restrict the daily routine of the diabetic more than necessary, mobile devices which are space-saving and simple to handle are used so that blood glucose concentration can be determined at any time.
[0003] Measurement of blood glucose concentration essentially requires two procedural steps. First, a liquid sample is generally produced by perforating the skin of the patient by means of a so-called lancet system, e.g., with the aid of a lancet needle driven by a spring system to generate a drop of blood. A blood quantity of 1.5 μL (or sometimes below 1 μL) is generally sufficient for modern measurement systems. Such lancet systems and lancing aids are known in the art and are commercially available in various embodiments. Such lancet systems are described, for example, in Publication Nos. DE 10 302 501 and DE 10 047 419. Lancing aids with magazine systems for holding and dispensing several lancets are also disclosed in these documents.
[0004] Second, the blood sample generated is then analyzed for blood glucose concentration. Diagnostic methods are usually used for this step and employ optical or electrochemical measuring methods. For example, a frequently used measuring method utilizes a special type of electrochemical test strip which can be designed such that a specified amount of blood is guided by a capillary system to an electrode system. This electrode system can, for example, be gold electrodes which are provided with a coating. The coating usually contains various enzymes and mediators and has the effect that charge carriers (for example, in the form of redox molecules) form within the blood sample at the electrodes. The concentration of the charge carriers are dependent on blood glucose concentration and can be determined by the gold electrodes and a suitable measuring system known to a person skilled in the art, for example, by means of a comparatively simple current-voltage measurement from which blood glucose concentration can be calculated.
[0005] Such a test device is known from U.S. Publication No. 20020170823, which can be used for substance analysis in body fluids such as for measuring blood glucose concentration. The described measuring device has a hand-held device and a base station in which the hand-held device and the base station can exchange data via an interface. The portable hand-held device is powered by lithium batteries.
[0006] In the first step described above for generating a blood sample, the lancet system usually first has to be manually tensioned when using systems and lancing aids known in the prior art. A spring system is typically manually tensioned, which requires a user to apply force in order to create the tension. However, this has disadvantages because children or people with physical limitations cannot usually use such lancing aids without help, and the use of such systems is inconvenient. Furthermore, operating some of these lancing aids with one hand is not always possible due to the required tensioning process.
SUMMARY OF THE INVENTION
[0007] Embodiments incorporating the present invention address the described disadvantages of the prior art and provide a portable lancing aid for collecting liquid samples and, in particular, for collecting blood samples for determining blood glucose concentrations. The portable lancing aid is easy to operate, especially for children or patients with physical limitations. Furthermore, additional embodiments provide a system for collecting liquid samples which has a portable lancing aid and a charging station for charging at least one long-term energy storage component of the portable lancing aid.
[0008] An exemplary embodiment of the portable lancing aid has at least one lancet system, wherein the lancet system has at least one lancet and at least one tensioning device for tensioning the lancet system. This lancet system can be one with a tensioning device that has a spring system such as those found in the prior art. This embodiment of the portable lancing aid is also flexible with regard to the design of the lancet and thus any lancet known to a person skilled in the art may be used. For example, the lancet can have at least one lancet needle, and in particular, a disposable lancet needle which for hygienic purposes is replaced by a new lancet needle after one or more lancing operations. Instead of lancet needles, the lancet can also have analogous designs such as prism-shaped, sharp-edged lancets. In particular, the portable lancing aid can have a single lancet or a plurality of lancets. In one embodiment with a plurality of lancets, a magazine for holding and/or dispensing lancets is advantageously used. An exemplary magazine is described in Publication No. DE 10 302 501.
[0009] In another embodiment, the portable lancing aid has at least one electromechanical actuator that tensions the tensioning device. The electromechanical actuator advantageously has at least one electric motor such as a direct current motor. It is further possible to use other electromechanical actuators such as magnetic systems (e.g., electromagnets) or piezoelectric systems. The electromechanical actuator can, for example, be directly connected to the lancet system, and in particular, with the tensioning device, or it can be connected by one or more gear units. The gear unit can, for example, have a drive mechanism via one or more drive belts or one or more gear wheels.
[0010] In addition, one embodiment of the portable lancing aid has at least one rechargeable long-term energy source that is connected to the electromechanical actuator in order to store electrical energy. In this embodiment, the energy source is used for storing electrical energy and remains substantially charged even after days if there is no electrical load. In particular, the electrical energy or charge should not decrease below 40% of the original energy or charge within about three days. This long-term energy source can be a battery and it has proven to be advantageous in various embodiments to use rechargeable batteries such as rechargeable lithium ion batteries and/or rechargeable lithium polymer batteries. It is also possible to use rechargeable nickel cadmium batteries and/or rechargeable nickel metal hydride batteries (NimH). However, it is also possible to use other types of rechargeable batteries. Thus, for example, capacitors having a long-term storage effect such as “supercaps” (also referred to as ultra capacitors) can also be used. Stored electrical energy can also be partially removed from these supercaps similar to batteries or rechargeable batteries and the self-discharge of these components is very low. Typical supercaps still have about 60-70% of their original charge after 30 days without load. Such components have the particular advantage over conventional rechargeable batteries in that they can be rapidly charged.
[0011] In another embodiment, the portable lancing aid has at least one interface that is accessible from outside the lancet system, wherein the long-term energy source can be connected to the interface in order to store electrical energy and be recharged. This interface can be one or more electrodes, such as metal electrodes, which are arranged on the outside of the housing. An appropriate complementary interface (e.g., a charging interface or charging station) can then be used to supply energy to these metal electrodes via connection to an appropriate power supply unit. This allows the energy source of the portable lancing aid to be recharged at regular intervals.
[0012] In another embodiment, the interface can also have a device for inductively charging the long-term energy source. For example, the interface can have a secondary coil of a transformer that is electrically connected to the energy source and a transformer core such that the energy source can be inductively charged essentially by putting a primary coil on the transformer core and applying an alternating voltage to this primary coil. This primary coil can, for example, be a component of a charging station into which the portable lancing aid is inserted.
[0013] The charging operation can take place when a charge level indicator shows that the charge level is below the minimum charge value for the long-term energy source. Hence, it has proven to be advantageous in one embodiment when the portable lancing aid has a charge level indicator to display the electrical charge level of the energy source for storing electrical energy. Such charge level indicators are known to a person skilled in the art and can, for example, have simple optical displays and/or acoustic indicators. In particular, the charge level indicator can have an optical segment display in the form of one or more light-emitting diodes which indicate the charge level of the energy source. Furthermore, the user of the portable lancing aid can also be given a warning such as an alarm such as an optical or acoustic signal when the charge level of the energy source reaches or falls below a specified minimum charge level. Thus, the user can be warned when the charge level of the energy source is no longer adequate to tension the lancet system or when the charge level is only sufficient for a few tensioning operations (for example, enough energy for a daily number of blood glucose measurements). This prevents the user or patient from not being able to carry out blood glucose measurements due to an unexpectedly uncharged energy source of the portable lancing device.
[0014] Embodiments of the portable lancing aid are advantageous over lancing aids in the prior art because the user no longer has to exert any mechanical force to tension the lancet system. The lancet system is instead tensioned by the electromechanical actuator. Hence, the portable lancing aid can also be used comfortably by patients with physical limitations or by children. The portable lancing aid can also be easily operated with one hand. If the charge level of the energy source and, in particular of the rechargeable battery, falls below a specified minimum value, the user or patient is warned accordingly so that the energy source can either be recharged or replaced. In addition, an embodiment of the device can also be provided in which the tensioning device is manually tensioned so that the lancet system can still be tensioned even when the energy source is empty or almost empty, but in this case the patient has to exert a mechanical force.
[0015] In an exemplary embodiment, the portable lancing aid can include at least one tensioning status sensor which detects the tensioning state of the tensioning device. Furthermore, means can be provided such as an appropriate electronic device or element (e.g., a microcomputer or other electronic components) to analyze the detected state of tension of the tensioning device. A tensioning operation can then be triggered depending on the detected state of tension. If it is, for example., found that the lancet system is in an untensioned state (e.g., after the lancet system has been triggered), the tensioning device can be automatically retensioned. The portable lancing aid is thus again ready for operation and further intervention by the user is not necessary. This embodiment is especially advantageous in combination with a portable lancing aid having a magazine for holding a plurality of lancets. In this embodiment, the system is designed such that a new lancet is selected automatically for each tensioning operation and prevents unhygienic multiple use of the same lancet. In an alternative embodiment, the lancet can be selected manually by the user, for example, by means of an appropriate rotary knob connected to the magazine.
[0016] In an advantageous embodiment, the system for collecting liquid samples includes a charging station to charge the long-term energy source of the portable lancing aid. In this embodiment, one or more portable lancing aids can be connected to a charging station. Such charging stations are known from various fields of the state of the art. In addition to the base station disclosed in U.S. Publication No. 20020170823, such systems are also disclosed in U.S. Pat. No. 6,524,240 for charging portable medical devices. An example of an electronic circuit of a charging station which prevents a portable instrument that is inserted into the charging station from being actuated when a charging current flows is disclosed in Publication No. DE 4036479.
[0017] The charging station can, for example, have at least one charging interface or coupling which can be connected to a source of electrical energy. This connection can be via one or more switches (for example selection switches or on/off switches) or via an electronic circuit so that an appropriate voltage transformation, an overvoltage protection, and/or an appropriate interval timer can be used which simplifies the handling of the system and makes a safer design. In this embodiment, it should be possible to connect the portable lancing aid to the charging station such that the charging interface or coupling is connected to the interface of the portable lancing aid. This connection between the portable lancing aid and the charging station can be accomplished by inserting the portable lancing aid into a corresponding recess of the charging station where the portable lancing aid is advantageously aligned during insertion such that the interface of the portable lancing aid is in electrical contact with the interface or coupling of the charging station.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above-mentioned aspects of the present invention and the maimer of obtaining them will become more apparent and the invention itself will be better understood by reference to the following description of the embodiments of the invention, taken in conjunction with the accompanying drawings, wherein:
[0019] FIG. 1 is a perspective view of a portable lancing aid with a portion of the external housing partially removed;
[0020] FIG. 2 is a perspective view of a system for collecting liquid samples showing the portable lancing aid of FIG. 1 and a charging station;
[0021] FIG. 3 is a top view of the charging station of FIG. 2 ; and
[0022] FIG. 4 is a flow chart illustrating a method for collecting blood samples for determining blood glucose concentration.
[0023] Corresponding reference numerals are used to indicate corresponding parts throughout the several views.
DETAILED DESCRIPTION
[0024] The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention.
[0025] FIG. 1 shows a perspective view of an embodiment of a portable lancing aid 110 . The portable lancing aid 110 has a housing 112 which is shown partially removed in FIG. 1 for the purpose of illustration. A housing cover 114 (see FIG. 2 ) can be removed from the remaining housing 112 in order to open the housing 112 by loosening screws 116 (see FIG. 2 ) which connect the housing cover 114 to the remaining housing 112 by appropriate threaded holes 118 .
[0026] The portable lancing aid 110 additionally has a lancet system 120 . The design and mode of operation of this lancet system 120 can, for example, be analogous to the embodiment of the lancet system 120 disclosed in U.S. Pat. No. 7,223,276. Other embodiments of lancet systems can be used such as the lancet system disclosed in U.S. Publication No. 20040260325. The aforementioned U.S. patent and publication are hereby incorporated by reference.
[0027] The lancet system 120 has a tensioning device 122 and a release or trigger button 124 . In addition, the lancet system 120 has a drum magazine 126 (mostly hidden in FIG. 1 ) to hold several disposable lancets 128 (not shown). An exemplary drum magazine 126 is described in U.S. Publication No. 20060008389, which is hereby incorporated by reference. The lancet system 120 also has a lancet cap 130 which has an exit hole in the front face (not shown) for the lancet 128 to extend through. The lancet cap 130 is designed to be detached from the lancet system 120 so that the drum magazine 126 can be replaced by removing the lancet cap 130 . Furthermore, the lancing depth of the lancets 128 can be adjusted by rotating the lancet cap 130 . The drum magazine 126 can be adjusted by means of a rotary knob 132 on the end of the lancet system 120 and thus a new and unused lancet 128 can be selected. In this embodiment, a disposable lancet 128 is selected manually by the user. In an alternative embodiment, a device can be provided in which a new disposable lancet 128 is selected from the drum magazine 126 after each lancing operation.
[0028] The portable lancing aid 110 also has a direct current motor 134 in the embodiment shown in FIG. 1 . The direct current motor 134 is connected to the tensioning device 122 of the lancet system 120 by means of a drive 136 having two gear wheels 138 , 140 . Thus, the tensioning device 122 of the lancet system 120 can be tensioned by means of the direct current motor 134 . As described above, other electromechanical actuators such as magnetic actuators, piezoactuators or other complex types of motors such as stepping motors can be used.
[0029] As shown in FIG. 1 , the portable lancing aid 110 has a tensioning status sensor 142 which can detect the tensioning state of the tensioning device 122 . In this embodiment, the tensioning status sensor 142 is a sensor which detects the position of the gear wheel 140 and according to this position determines whether the tensioning device 122 is tensioned. This tensioning status sensor 142 can, for example, also be a component of the direct current motor 134 where an angular position of the direct current motor 134 is determined by the position of the gear wheels 138 , 140 and/or the drive 136 . The tensioning status can be detected if a stepping motor is used instead of a direct current motor 134 . However, stepping motors are relatively complicated. Two or more tensioning status sensors 142 can be used instead of an individual status sensor 142 where, for example, a first tensioning status sensor 142 detects the tensioned status of the tensioning device 122 and a second tensioning status sensor 142 detects the untensioned status of the tensioning device 122 .
[0030] The portable lancing aid 110 shown in FIG. 1 has a rechargeable lithium ion battery 144 and an electronic control circuit board or element 146 . The rechargeable lithium ion battery 144 supplies the direct current motor 134 and the electronic control circuit board or element 146 with electrical energy. The high energy density of the rechargeable lithium ion battery 144 typically allows up to about 100 tensioning operations of the tensioning device 122 by the direct current motor 134 with minimal battery size. Furthermore, the discharge of such rechargeable lithium ion batteries 144 is relatively low and thus average use of the portable lancing aid 110 (typically between five and fifteen times per day) requires only periodic recharging of the rechargeable lithium ion battery 144 .
[0031] The electronic control circuit board or element 146 of the portable lancing aid 110 is designed such that the tensioning status of the tensioning device 122 detected by the tensioning status sensor 142 is used to automatically tension the lancet system 120 . As soon as the tensioning status sensor 142 detects that the tensioning device 122 of the lancet system 120 is in an untensioned state (e.g., after triggering the lancet system 120 ), the direct current motor 134 is started automatically by the electronic control circuit board or element 146 so that the tensioning device 122 is retensioned and the portable lancing aid 110 is thus again ready for operation. Other embodiments of the portable lancing aid 110 are possible in which tensioning the tensioning device 122 by the direct current motor 134 is not triggered until the user makes an affirmative action such as by actuating an appropriate input button on the surface of the portable lancing aid 110 .
[0032] In the embodiment shown in FIG. 1 , the portable lancing aid 110 has an interface 148 which is arranged on the electronic control circuit board or element 146 and protrudes through the housing cover 114 when the housing 112 is closed and can thus be accessed from the outside. This interface 148 can have one or more metal contacts. The rechargeable lithium ion battery 144 can be electrically charged via this interface 148 . Furthermore, the portable lancing aid 110 can also be designed such that information can be exchanged via the interface 148 , for example, in order to supply the electronic control circuit board or element 146 with information about the patient (e.g., information about the lancing depth of the lancet system 120 ).
[0033] An embodiment of a system for collecting liquid samples 210 is shown in FIG. 2 . The system 210 has a portable lancing aid 110 according to the embodiment shown in FIG. 1 (with a closed housing cover 114 ) and a charging station 212 . The portable lancing aid 110 is inserted into an appropriately shaped recess 214 of the charging station 212 . This charging station 212 is also shown from above in FIG. 3 where the recess 214 is better illustrated. The charging station 212 has a housing 216 into which the recess 214 forms, and the recess is designed such that the housing 112 of the portable lancing aid 110 can be inserted therein. In this arrangement, the interface 148 of the portable lancing aid 110 is in electrical contact with a charging interface or coupling 310 of the charging station 212 when the portable lancing aid 110 is inserted into the charging station 212 . The charging interface or coupling 310 is further connected to a main connection or power cord 218 . The charging interface or coupling 310 is advantageously not directly connected to the main connection or power cord 218 , but rather via an appropriate electronic circuit that can have switches, an overvoltage protection, a voltage transformer, and/or other electronic components. This ensures that when the portable lancing aid 110 is inserted into the charging station 212 , the rechargeable lithium ion battery 144 of the portable lancing aid 110 is electrically charged and is not damaged by incorrect handling or electrical interferences (power fluctuations or short circuits).
[0034] The charging station 212 is additionally provided with a flat underside or bottom surface 220 such that the charging station 212 can be safely positioned on flat surfaces without tilting even after the portable lancing aid 110 is inserted. Other exemplary charging stations 212 may have several recesses 214 and charging interfaces or couplings 310 to simultaneously charge several portable lancing aids 110 for use, such as, in hospitals.
[0035] FIG. 2 also shows that the portable lancing aid 110 has a charge level indicator 222 on the housing cover 114 . This charge level indicator 222 can also be positioned at other sites on the housing 112 and is designed as a segment display having five light-emitting diodes in this embodiment. For example, all five light-emitting diode segments may light up corresponding to the highest charge status of the rechargeable lithium ion battery 144 and none of the segments of the charge level indicator 222 may light up corresponding to the rechargeable lithium ion battery 144 being completely discharged. The light-emitting diode segments can, for example, also have different colors to indicate a low charge status to the user. In particular, the charge level indicator 222 can be actuated by the electronic control circuit board or element 146 .
[0036] FIG. 4 shows an exemplary method where the system 210 of FIG. 2 is used to collect liquid samples. The steps shown in FIG. 4 do not necessarily have to be carried out in the order shown and other steps that are not shown can also be performed.
[0037] In describing the steps involved in the method of FIG. 4 , reference is made to the embodiments shown in FIGS. 1 and 2 . In the first step 410 , a disposable lancet 128 is selected, for example, by means of the rotary knob 132 of the portable lancing aid 110 of FIG. 1 . In the second step 412 , the tension of the tensioning device 122 is detected by means of a tensioning status sensor 142 . Subsequently, the detected tensioning status is checked in step 414 . If it is determined (step 416 ) that the tensioning device 122 is in an untensioned state, step 418 is carried out and the tensioning device 122 is tensioned by means of the direct current motor 134 . If, in contrast, it is determined in step 414 that the tensioning device 122 is already in a tensioned status (step 420 ), then step 418 (tensioning of the lancet system 120 ) is skipped. The lancet system 120 is now ready for operation and is triggered in step 422 (for example, by pressing the trigger button 124 ).
[0038] The detection of the tensioning status in step 412 and checking the tensioning status in step 414 can be carried out continuously or periodically so that the lancet system 120 is kept in a tensioned state. Alternatively, as described above, the tensioning 418 of the lancet system 120 can also be initiated by user input.
[0039] Finally in step 424 , the charge status of the rechargeable lithium ion battery 144 is detected. This detection of the charge status in step 424 does not necessarily take place after the triggering step 422 , but rather the detection of the charge status can also, for example, be carried out continuously or at regular intervals or at other stages in the method of FIG. 4 . The charge status is indicated to a user of the portable lancing aid 110 in step 426 by means of the charge level indicator 222 . A query can also be carried out in step 428 in which the charge status is checked to determine whether the charge status is below a specified minimum charge value. If the charge falls below the minimum charge value (step 430 ), the user is alerted in step 432 , for example, by an acoustic or optical warning signal. Subsequently in step 434 , the rechargeable lithium ion battery 144 is recharged by inserting the portable lancing aid 110 into the charging station 212 as shown in FIG. 2 , and the charging station 212 is supplied with electrical energy via the main connection or power cord 218 .
[0040] While exemplary embodiments incorporating the principles of the present invention have been disclosed hereinabove, the present invention is not limited to the disclosed embodiments. Instead, this application is intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
LIST OF REFERENCE NUMERALS
[0041] 110 portable lancing aid
[0042] 112 housing
[0043] 114 housing cover
[0044] 116 screws
[0045] 118 threaded holes
[0046] 120 lancet system
[0047] 122 tensioning device
[0048] 124 trigger button
[0049] 126 drum magazine
[0050] 128 disposable lancets
[0051] 130 lancet cap
[0052] 132 rotary knob
[0053] 134 direct current motor
[0054] 136 drive
[0055] 138 gear wheel
[0056] 140 gear wheel
[0057] 142 tensioning status sensor
[0058] 144 rechargeable lithium ion battery
[0059] 146 electronic control circuit board or element
[0060] 148 interface
[0061] 210 system for collecting liquid samples
[0062] 212 charging station
[0063] 214 recess
[0064] 216 housing of the charging station
[0065] 218 mains connection or power cord
[0066] 220 flat underside
[0067] 222 charge level indicator
[0068] 310 charging interface or coupling
[0069] 410 selection of a lancet
[0070] 412 detection of a tensioning status
[0071] 414 checking the tensioning status
[0072] 416 untensioned status
[0073] 418 tensioning of the lancet system
[0074] 420 tensioned status
[0075] 422 triggering the lancet system
[0076] 424 detecting a charge status
[0077] 426 indicating the charge status
[0078] 428 checking whether it falls below the minimum charge status
[0079] 430 falls below the minimum charge status
[0080] 432 output of a warning signal
[0081] 434 charging | A portable lancing aid for providing liquid samples comprises a lancet system having at least one lancet, a tensioning device, and an electromechanical actuator. The tensioning device can be tensioned by the electromechanical actuator. The portable lancing aid may further include an energy source for storing electrical energy that is connected to the electromechanical actuator. Additionally, the portable lancing aid may include an interface for charging the energy source where the interface is externally accessible from the lancet system. The invention is ergonomical and easy to handle for children and patients with physical limitations. Furthermore, a lancing system for collecting liquid samples is provided with a portable lancing aid that is detachably mountable to a charging station for charging the portable lancing aid. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a computerized knowledge mining, intelligence analysis, and knowledge management system, specifically to analytical logic (i.e. knowledge) capturing, constructing, accumulating, and sharing.
2. Related Art
Intelligent analysis process often involves a variety of data and reasoning logic. In order to make better decisions or analyses, people need to be able to utilize multi source knowledge. The biggest issue is how we utilize multi source knowledge understandably and efficiently. For example, when developing a new stock performance evaluation method, we may like to combine different analytical logic or methods such as technical analysis, fundamental analysis, chart analysis, volume analysis, and market psychological analysis, which raises some questions. Can people quickly build the method at their skill levels? How can people combine different analytical logic and/or methods together without losing logic clarity, flexibility, scalability, and share ability? Can the combined method be easily updated and extended? All of these questions boil down to a single issue: how do we capture or computerize human analytical logic that can be easily shared, especially across analysis areas and/or industries.
Although any analytical logic can be constructed by “CASE” or “IF . . . THEN . . . ELSE . . . ” programming statements, the readability, scalability, and changeability of the analytical logic often become barriers for sharing and updating knowledge when the analysis issue become more complicated.
We all agree that human analytical logic or reasoning processes can be well presented by a (decision or knowledge) tree structure. Because of the unique tree's characteristics such as independency of peer nodes and single parent node, the tree structure is a most scalable, flexible, and commonly used analytical structure. Although many decision-tree construction methods (e.g. Naïve-Bayes, Classification, Fuzzy, and Neuron Network.) have been developed, the structures of nodes are often not uniformed or standardized. Different decision-tree construction methods use different node structures. Even within the same construction method, sometimes, many different node structures (e.g. decision node, classifier node, data/factor node) are used. For a decision tree with multiple node structures, the analysis process, logic modification, and logic sharing (e.g. embed a decision tree into another decision tree that is built with a different construction method.) are often complicated, inflexible, and inefficient.
SUMMARY OF THE INVENTION
The present invention provides an open knowledge structure that defines a uniform knowledge node. Each knowledge node has a plurality of components and attributes. According to the present invention, the knowledge node includes a knowledge cell, a processing unit with a user specified evaluation function, a decision set, a user specified weight function, a learning matrix, and a user specified learning function. The values (i.e. basic knowledge or judgments) of knowledge cell can be static or dynamic. The static value can be a constant number or string. The dynamic value can come from an intelligent analysis function, a survey function, a data-mining tool, or an analysis module. A knowledge node can have zero to many inputs.
The present invention defines open structure and architecture for constructing dynamic and distributed intelligence analysis modules (i.e. knowledge trees). The knowledge tree can be stored in knowledge bases that are built with common used commercial databases (e.g. Oracle, DB2, Sybase, SQL Server and MS Access), data file, or executable file. According to the present invention, a knowledge tree has at least one knowledge node. The knowledge nodes are interlinked by using address-based link methods. The knowledge nodes or sub-trees of a knowledge tree can be stored in either identical or different knowledge bases that reside on either the same knowledge base server or different knowledge base servers.
The present invention introduces a method that can simplify the knowledge capturing processes, programming codes, and analysis processes. With the open and uniform knowledge structure and architecture, the analytical logic can be understood easily, shared across analysis areas and systems effectively, updated dynamically, and processed efficiently with peer-to-peer technology. According to the present invention, the knowledge trees can be effectively stored and managed in distributed manner. In summary, the present invention provides a knowledge-mining tool that enables people to construct their analytical logic using a variety of existing knowledge and/or methods.
Further features and advantages of the invention, as well as the structure and operation of various embodiments of the invention, are described in detail below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
The present invention will be described with reference to the accompanying drawings, wherein:
FIG. 1 shows visual knowledge cell structure using m×n matrix in accordance with one embodiment of the present invention.
FIG. 2 illustrates an example of physical storage for a knowledge cell (n×n) in accordance with one embodiment of the present invention.
FIG. 3 illustrates a knowledge mining method that is used to capture basic decisions or judgments for a knowledge cell in accordance with one embodiment of the present invention.
FIG. 4 shows major components of a knowledge node in accordance with one embodiment of the present invention.
FIG. 5 illustrates a hit-miss matrix of the knowledge node that uses for knowledge learning in accordance with one embodiment of the present invention.
FIG. 6 is a flow diagram illustrating a method of a node's knowledge learning process of the present invention.
FIG. 7 is a flow diagram illustrating a method of a node's knowledge adjusting process of the present invention.
FIG. 8 illustrates an example of a distributed knowledge tree using the open knowledge tree construction method of the present invention.
FIG. 9 illustrates three basic group analysis modules using the open knowledge tree structure in accordance with one embodiment of the present invention.
FIG. 10 is a flow diagram illustrating an analysis process method using the knowledge tree in accordance with one embodiment of the present invention.
FIG. 11 illustrates a web-based open knowledge computer system wherein the knowledge tree has been constructed, stored, shared and processed.
In the drawings, like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides an open knowledge structure (i.e. knowledge cell) and a method for constructing the Knowledge Node. Furthermore, the present invention provides a method and a computer system for inducing an Open Knowledge Tree. The Open Knowledge Tree is constructed using the knowledge nodes and dynamic address-based link methods, all knowledge nodes having the identical plurality of attributes. The Open Knowledge Tree utilizes the advantages of both decision tree structures (e.g. scalability, segmentation, and independency) and networking technologies (e.g. distributed and dynamic link).
The present invention can be used in knowledge (i.e. analytical logic) discovery and construction, intelligence analysis, intelligent device control, and knowledge management. Given the description herein, it would be obvious to one skilled in the art to implement the present invention in any general computer platform including, but not limited to, a computer processor (single chip or multi-chips), high-end to low-end workstations/servers, virtual machine (e.g. Java-created application or .Net created application), and network architectures (e.g. client/server, intranet, internet, wireless, intermediate or wide area networks).
Description in these terms is provided for convenience only. It is not intended that the invention be limited to application in this example environment. In fact, after reading the following description, it will become apparent to a person skilled in the relevant art how to implement the invention in alternative environments.
FIG. 1 shows an open knowledge cell structure 100 in accordance with one embodiment of the present invention. The open knowledge cell structure 100 includes a (m×n) matrix 110 , decision functions D j (j=1,2, . . . , n) 120 , action functions A i (i=1,2, . . . , m) 130 and factors F j (j=1,2, . . . , n) 140 .
Each column of the matrix 110 has only one decision function value that is generated by the corresponding decision function D j 120 . The value of the decision function D j 120 indicates which action function A i (i=1,2, . . . , m) 130 will be used or executed. Each column F j of the knowledge cell 100 has one and only one decision function D j 120 . The action functions, A i (i=1,2, . . . , m) 130 , are usually arranged in a specific order (e.g. A i is an action function for the worst case or the most pessimistic decision and A m is an action function for the best case or the most optimistic decision. The functions are in an order from the worst to the best.). The value of the decision function D j 120 can be constant value or generated by a user specified function. The action function A i 130 can be a constant value (e.g. a decision or forecasting message), a user specified function, a user specified function link (e.g. an analysis report link or function call), or a user specified control command (e.g. an event trigger or control signal). The factor F j 140 can be a constant value, a user specified function, or user specified function link (e.g. a factor range generator). When using function links, the values of the knowledge cell 100 are dynamic, which enables the intelligent analysis process to always use the latest knowledge.
FIG. 2 shows an example of storing a (n×n) knowledge cell that uses a (3×n) unit storage space, where each value of the decision function D j determines which action function A i to be used for a factor F j .
FIG. 3 shows a knowledge-mining method 300 in accordance with one embodiment of the present invention. The knowledge-mining process includes a knowledge cell 310 , a user specified knowledge normalization function 320 and a knowledge collecting method 330 , 340 , 350 , 360 , or 370 .
The knowledge-mining method 300 can create or update a knowledge cell 310 that is defined in FIG. 1 . The knowledge-collecting function 330 provides an input interface for users to enter or define action, decision and/or factor range values manually. The knowledge-collecting methods 340 and 350 provide an interface and functions for users to define or link survey and/or data mining methods to generate knowledge cell values. The knowledge-collecting methods 360 and 370 provide functions for users to link existing analytic modules (e.g. knowledge trees) and/or analytic applications as knowledge cell values. The knowledge-normalization module 320 maps collected actions, decisions, factor values into range 1 . . . m or 1 . . . n.
FIG. 4 shows a knowledge node 400 , wherein the knowledge cell is incorporated in accordance with one embodiment of the present invention. The knowledge node 400 is comprised of a weight unit 410 , a processing unit 420 , a knowledge cell 430 , a learning function 440 , a decision set 450 , and a learning matrix 460 .
The knowledge node 400 is a basic component for building any analysis module in accordance of the present invention. The weight unit 410 can define the node's weight in the analysis process. The node's weight can be pre-set by a user or dynamically generated by a user specified weight function. The processing unit 420 is comprised of destination (e.g. parent node or analysis result receiver) address, source (e.g. children node or function link) addresses, and a user specified input evaluation function. The knowledge cell 430 that is defined in FIG. 1 stores a basic decision. The basic decision means that a decision maker can make a quick judgment on a factor at his or her knowledge level. The learning function 440 can adjust decision values 120 of the knowledge cell 430 in terms of hit-miss ratio in the learning matrix 460 . The decision set 450 can store up to p previous decision results. The previous node decision results can be used for knowledge learning. The user can decide the size (p) of the decision set 450 in terms of analysis needs. The learning matrix 460 keeps hit-miss counts for each factor F j (j=1,2, . . . , n) 140 .
FIG. 5 shows an example of a learning matrix that keeps decision hit-miss counts. The hit-miss counts of a node decision are categorized into miss-low, hit and miss-high in this example. Since the action functions, A i (i=1,2, . . . , m) 130 , are arranged in a specific order, the decision miss-low means that a decision A q was made but it should be the decision A r where r>>q(1); the decision hit means that the decision A q was right (i.e. r=q or r is close to q); the decision miss-high means that a decision A q was made but it should be the decision A r where r<<q (i.e. r is “significantly” less than q, which user defines significantly greater range). A user specified hit-miss function counts the number of decision hits or misses comparing decision values, d ij (t)=>A q ε{A 1 , . . . A m } that was made on a factor F k ε{F 1 , . . . F n } at time t, with a correct decision value, m ij (t)=>A r ε{A 1 , . . . A m } that should be made at time t. For example, if q<<r then add 1 to counter MISS_LOW k ; If q=r or q is close to r then add 1 to counter HIT k ; If q>>r then add 1 to counter MISS_HIGH k .
For the decision process, the node's processing unit 420 collects all input factors' values and weights {(d (i+1)1, w 1 ), . . . , (d (i+1)s, w s )} from children nodes, linked functions and/or users, where the value d (i+1)j ε{1, 2, . . . n}, j=1,2, . . . , s. A user specified evaluation function determines a final factor value k that determines the node decision. For example, a collected input factor-weight set is {(4,1), (2,1), (4,1), (5,1), (3,1), (2,1), (1,1), (4,1), (3,1), (2,1)} where n of the knowledge cell in FIG. 1 is equal to 5 (i.e. n=5) and all weights are equal. Assume that an Optimistic Majority evaluation function is used, which means r is a more optimistic choice than q if r>q. Since the factor value 2 and 4 are majority input groups that have equal inputs, the factor value 4 is selected because 4 is more optimistic choice than 2 . The final factor value kε{1, 2, . . . n}=>(i.e. determines) the factor F k =>D k =>A q where q ε{1, 2, . . . m} and A q is a decision of node (i, j) at time t or d ij (t)=A q (i, j). The node decision d ij (t) and a weight value w ij generated by weight function 410 can be either a final decision or used as an input factor of its parent node. The node decision d ij (t) and F k 140 can be stored into the decision set 450 as node's learning data.
FIG. 6 is a flow diagram 600 illustrating the method inducing a node learning process of the knowledge tree in accordance with one embodiment of the present invention. The node learning process is comprised of node decision collecting, hit-miss counting and knowledge adjustment steps.
Referring to FIG. 6 in a step 605 , the node (i, j) receives a set of correct decision and factor at time t or m ij (t)={A r (i, j),F p (i, j),t}. In a step 610 , check if the collected decision A r (i, j) is valid (e.g. is not NULL). If A r (i, j) is valid, the flow moves to a step 615 , where it begins to perform steps 615 - 650 for hit-miss counting and then the flow moves to a step 655 for knowledge adjustment. If A r (i, j) is invalid (e.g. is NULL or no correct decision is received), the flow moves to a step 655 for knowledge adjustment. The step 615 retrieves the node decision at time t or M ij (t)=(A q (i, j),F k (i, j), t) from the learning matrix 460 . Next, in a step 620 , it determines if p=k for F p (i, j) and F k (i, j). If p=k (i.e. a correct factor value was used.), the flow moves to a step 630 . If p<>k (i.e. an incorrect factor value was used.), the flow moves to a step 625 , where a node decision A u (i, j) for the factor value F p (i, j) is used as the node decision A q (i, j); at time t and then the flow moves to a step 630 . In the step 630 , it determines if r=q or r is close to q for A r (i, j) and A q (i, j). If r=q or r is close to q (i.e. a correct node decision was made.), the flow moves to a step 635 , where hit counter HIT p (i, j) is added by one and then the flow moves to a step 655 . If r>>q (i.e. r is “significantly” greater than q or the node decision was below the correct decision.) in a step 640 , the flow moves to a step 645 , where miss-low counter MISS_LOW p (i, j) is added by one and then the flow moves to a step 655 . If r<<q (i.e. r is “significantly” greater than q or the node decision was above the correct decision.), the flow moves to a step 650 , where miss-high counter MISS_HIGH p (i, j) is added by one and then the flow moves to a step 655 .
Next, in a step 655 , it determines if condition for adjusting the decision function D p (i, j) is met (e.g. if the total of the hit and miss counts for the factor F p (i, j) reaches to 1000?). If the condition is met, the flow moves to a step 660 , where the decision function D p (i, j) is adjusted and then the condition for adjusting the decision function D p (i, j) is re-set. The step 665 sets F p (i, j) as a correct decision of all children nodes (i+1, j) of the node (i, j). The flow diagram 600 can start the node-learning process at any node (i, j) but it usually starts at the root node. The node-learning process is recursively performed for all descendant nodes of the node (i, j).
FIG. 7 is a flow diagram 700 illustrating a more specific embodiment of the step 665 of FIG. 6 for inducing a node knowledge adjusting process in accordance with one embodiment of the present invention. Step 710 retrieves hit-miss counts, {MISS_LOW p (i, j), HIT p (i, j), MISS_HIGH p (i, j)} and then the flow moves to a step 720 . The step 720 determines if MISS_LOW p (i, j)>>HIT p (i, j) (i.e. miss-low count is “significantly” greater than hit count, which user defines significantly greater range). If the miss-low count is significantly greater than the hit count, the flow moves to a step 730 , where it adjusts the decision function D p (i, j) value higher (e.g. if D p (i, j) is in A q (i, j)'s row and q<m, set D p (i, j) to A q (i, j)'s row) and then the flow moves to a step 760 . If the miss-low count is not significantly greater than the hit count, the flow moves to a step 740 , where it determines if MISS_HIGH p (i, j)>>HIT p (i, j) (i.e. miss-high count is “significantly” greater than hit count, which user defines significantly greater range). If the miss-high count is significantly greater than the hit count, the flow moves to a step 750 , where it adjusts the decision function D p (i, j) value lower (e.g. if D p (i, j) is in A q (i, j)'s row and q>1, set D p (i, j) to A q−1 (i, j)'s row) and then the flow moves to a step 760 . If the miss-high count is not significantly greater than the hit count, the flow moves to a step 760 . The step 760 re-sets the adjusting schedule for the decision D p (i, j).
FIG. 8 illustrates an example of a distributed knowledge tree that is built in the open knowledge tree structure of the present invention. The knowledge tree 800 is comprised of knowledge nodes (KN) 810 and/or sub-trees 820 , 830 , 850 , and 860 . The sub-trees 850 and 860 are independent knowledge trees or analysis modules (AM) that are linked through Internet, Intranet, or wireless network 840 .
FIG. 9 illustrates three basic group analysis modules using the open knowledge structure in accordance with one embodiment of the present invention, where u i v i or w i is a set of input factor values from a user/analyst or specific analysis modules/functions. The group analysis module (AM) 910 uses different sets of input factor values, where the group analysis process is at the factor collecting level. The group analysis module 920 repeatedly uses the same analysis module and uses different sets of input factor values from different analysis groups for each analysis module, where the group analysis process is at the factor collecting and analytical result levels. The group analysis module 930 uses different analysis modules and different sets of input factor values from different analysis groups for each analysis module, where the group analysis process is at the factor collecting, analytical logic and analytical result levels.
FIG. 10 is a flow diagram 1000 illustrating an analysis process method using the knowledge tree in accordance with one embodiment of the present invention. The analysis process can start from one or many leaf nodes of a selected knowledge tree and ends up at the root node. The root node output is the analysis result or decision. For the explanation reasons, the flow diagram 1000 of FIG. 10 only processes one node at each time. The analysis process of the present invention can use multiple tasks, sessions or threads to process multiple peer nodes or peer sub-trees at the same time.
Referring to FIG. 10, in a step 1010 , it adds all leaf nodes of the knowledge tree into an analysis processing set in a specific order (e.g. from the most left leaf node to the most right one). Next, in a step 1020 , the analysis process extracts the first node as the current processing node. In a step 1030 , it collects and evaluates all input factor values of the current node to determine its output value, where the factor values can be obtained from children nodes' outputs, users' inputs and/or functions' outputs. Next, in a step 1040 , it determines if the current node has a parent node. If it has no parent node (i.e. it is the root node), the flow moves to a step 1050 , where an analysis result, decision, or control action is generated in terms of the current node's output value and ends the analysis process. If the current node has a parent node, the flow moves to a step 1060 , where it determines if the parent node is in the analysis processing set. If the parent node is already in the analysis processing set, the flow moves to the step 1020 . If the parent node is not in the analysis processing set, the flow moves to a step 1070 , where it adds the parent node of the current node into the end of the analysis processing set and then the flow moves to a step 1020 , where, for each node in the analysis processing set, the flow recursively performs steps 1020 - 1040 until the root node is reached and processed or the analysis processing set is empty.
FIG. 11 shows an open knowledge computer system 1100 wherein the knowledge tree has been constructed, stored, shared, managed, and processed. Specifically, the open knowledge computer system 1100 includes a Knowledge Warehouse 1105 and an Open Intelligence Server 1120 . Furthermore, the Open Intelligence Server 1120 is comprised of a Database Networking Connection Function Library 1125 , a Knowledge Ming Tool 1130 , a Knowledge Builder 1135 , a Knowledge Management Unit 1140 , a Knowledge Search Engine 1145 , a Intelligent Analysis Processor 1150 , and a User Interface 1155 .
The Knowledge Warehouse 1105 is a set of virtually or physically linked knowledge bases that are built on the same or different commercial databases such as Oracle, MS SQL Server, Sybase, DB2 and MS Access. The Open Intelligence Server can access knowledge bases remotely through network 1110 or locally 1115 through I/O Data Bus that the knowledge base resides on the Open Intelligence Server. Users 1160 - 1170 can perform knowledge construction, intelligence analysis and knowledge management through the User Interface 1155 and network 1175 .
In summary, the present invention discloses an open knowledge structure, a method to construct an open knowledge node, and a method to construct an analysis module or knowledge tree with open and dynamic knowledge tree architecture, called Open Knowledge Tree. Furthermore, the present invention discloses a method of building an Open Knowledge Computer System for knowledge mining, knowledge learning, analysis processing, and knowledge management.
While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. | The present invention relates to a computer based knowledge system for assisting persons in making decisions and predictions using a computerized knowledge tree with fuzzy logic, statistics, and mathematics methods. The invention defines a knowledge tree structure to represent and store human or data-mining knowledge. The knowledge tree has decision/prediction output(s), knowledge, weights, input factors, etc. The knowledge system enables a user to build knowledge trees based on their knowledge, expert knowledge, and data-mining knowledge. The knowledge tree can be updated dynamically with knowledge mining functions or self-learning functions. A decision or prediction is made by calculating a knowledge tree based on the input factors. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a new anthracycline glycoside antineoplastic agent and, more particularly, to a new oxygen analogue of the anthracycline antibiotic carminomycin.
2. Prior Art
As described in M. G. Brazhnikova et al., J. Antibiot., 27:254-259 (1974), G. F. Gause et al, Cancer Chemother. Rep. 58:255-256 (1974), M. C. Wani et al, J. Am. Chem. Soc. 97:5955-5956 (1975) and West German Pat. No. 2,362,707, the anthracycline glycoside carminomycin is known to be a clinically useful antineoplastic agent. However, it produces certain undesirable side effects, common to many antineoplastics agents, which limit its use in chemotherapy. In particular, it produces a cumulative, dose-related cardiotoxicity which limits the total dosage that can be administered to a patient and the duration of treatment.
Preparation of a glycoside of daunorubicin is described in E. F. Fuchs et al, Carbohydr. Res., 57: C36 (1977). Preparation of glycosides of ε-rhodomycinone is described in H. S. El Khadem et al, J. Med. Chem., 20:957-960 (1977). Preparation of 2-deoxy-L-fucopyranosyl-ε-pyrromycinone and 2-deoxy-D-erythro-pentopyransoly-ε-pyrromycinone, - cdaunomycinone, and - carminomycinone and their dio-O-acetyl derivatives is described in H. S. El Khadem, Carbohydr. Res., 65: C1 (1978).
SUMMARY OF THE INVENTION
The present invention provides a new oxygen analogue of carminomycin which can be represented by the following formula: ##STR1## This carminomycin analogue can be prepared by coupling an appropriate glycosyl halide, namely, 3,4-di-O-acetyl-2,6-dideoxy-α-L-lyxo-hexopyranosyl bromide, or the corresponding chloride, to carminomycinone. The resulting acetylated blocked glycoside intermediate is deacetylated to produce the above oxygen analogue of carminomycin which is effective for inhibiting the growth of tumors such as leukemia L1210.
The invention also provides a method for inhibiting the growth of certain mammalian tumors such as L1210 leukemia by administering therapuetically effective amounts of the above compound to experimental animals afflicted with such tumors.
DETAILED DESCRIPTION
The overall reaction scheme of a preferred process for preparing the novel carminomycin analogue of the invention can be represented as follows: ##STR2## wherein X is Br or Cl.
The starting compound carminomycinone (I) can be prepared in a conventional manner such as by hydrolyzing carminomycine. This can be accomplished by refluxing a 0.1 N hydrochloric solution of carminomycin for 2-3 hours and filtering the precipitate carminomycinone crystals from the solution.
The glycosyl halide 3,4-di-O-acetyl-2,6-dideoxy-α-L-lyxo-hexopyranosyl bromide or chloride (II) coupled with carminomycinone can be prepared in the manner as described in H. S. El Khadem et al, Carbohydr. Res., 58:230-234 (1977). That is, L-fucose tetraacetate is treated with hydrogen bromide in acetic acid to obtain the corresponding glycosyl bromide which is treated with an activated zinc dust suspension at a reduced temperature, the cold mixture filtered and the filtrate extracted with chloroform or the like. The resulting di-O-acetyl-L-fucal is treated with a dry stream of hydrogen bromide or hydrogen chloride to produce the desired glycosyl halide.
The coupling reaction is carried out by refluxing one molar equivalents of carminomycinone and the glycosyl halide under Koenig-Knorr conditions using a mercuric bromide-mercuric cynanide catalyst. The reaction product is filtered to remove solids and the mercuric salts. The filtrate is evaporated to dryness to remove the solvent. The solid residue is dissolved in a suitable solvent, such as chloroform, and the resulting solution is washed to remove remaining mercuric salts. After the solution is evaporated to dryness, the resulting solid residue is dissolved in a suitable solvent, such a diethyl ether, and sugar components which do not react with carminomycinone are removed in a suitable manner, such as with a column chromatograph, to yield the blocked acetylated glycoside intermediate (III).
The glycoside intermediate (III) is deacetylated in a suitable manner to produce the carminomycin analogue of the invention. This can be accomplished by dissolving the acetylated glycoside in a suitable solvent, such as methanol, and adding the solution to a sodium methoxide-methanol solution containing an excess of sodium methoxide. The desired carminomycinone analogue 2-deoxy-L-fucopyranosyl carminomycinone (IV) is extracted by chloroform or the like.
The compound of the invention can be used as an active ingredient in pharmaceutical compositions including a pharmaceutically acceptable carrier. Such compositions could also include one or more active antibacterial and/or antineoplastic agents and may be in any form suitable for the desired mode of administration. For instance, the pharmaceutical composition can be in a solid form for oral administration, such as tablets, powders, granules or capsules, liquid form for oral administration such as syrups, solutions or suspensions and liquid preparations for parenteral administration, such as solutions, emulsions, or suspensions.
The pharmaceutical composition is administered in dosages which provide a concentration of the carminomycinone glycoside greater than the minimum inhibitory concentration for the leukemia tumor. The actual dosage will vary depending on such things as the formulation of the composition, mode of administration, age, weight, diet and reaction sensitivities of the afflicted host, and severity of the tumor. It is well within the skill of the art, after reviewing the guidelines disclosed herein, to determine the optimum dosage for a given situation by using conventional dosage tests.
Without further elaboration, it is believed one skilled in the art can, by using the preceeding description, utilize the present invention in its fullest extent. The following examples are presented for the purpose of illustration and should not be construed as limitations to the invention.
EXAMPLE 1
Preparation of 2-deoxy-L-fucopyranosyl carminomycinone
300 mg of carminomycin in 30 ml of 0.1 N hydrochloric acid was refluxed with stirring for 3 hours. This solution was cooled and filtered. The wet red crystals were dried in a vacuum desiccator over sodium hydroxide overnight to yield about 200 mg of carminomycinone (I).
A mixture comprising 200 mg carminomycinone, 1.0 g finely divided molecular sieves 3A, 200 mg mercuric bromide, 20 mg mercuric cynnanide, 200 mg 3,4-di-O-acetyl-2,6-dideoxy-α-lyxo hexopyranosyl bromide (II) and 20 ml tetrahydrofuran was refluxed with stirring for 1 hour. An additional 200 mg of the glycosyl bromide was added to the mixture and the mixture refluxed for another hour. The solution was filtered to remove the molecular sieves and the mercuric compounds and the sieves were washed with chloroform. The combined filtrates were evaporated to dryness, the solid residue dissolved in chloroform and the resulting solution was washed several times with a 20% potassium iodide solution to remove remaining mercuric compounds. The solution was then dried over anhydrous sodium sulfate and evaporated to dryness. The solid residue was dissolved in absolute diethyl ether containing a small amount of chloroform and the solution was applied to a silica gel column chromatograph (washed with absolute diethyl ether) to remove sugar components which had not reacted with carminomycinone. The blocked acetyleted glycoside intermediate (III) was eluded with chloroform containing 3% methanol.
The glycoside-containing fractions from the chromatograph were evaporated to dryness. The solid residue was dissolved in 20 ml of methanol and the resulting solution was added to a freshly prepared, room temperature sodium methoxide/methanol solution containing an excess of sodium methoxide to deacetylate the glycoside. After 20 minutes, the solution was poured into a separatory funnel containing a sodium hydrogen sulfate solution and the desired oxygen analogue of carminomycin (IV) was extracted with chloroform. The extract was dried over anhydrous sodium sulfate and evaporated to dryness. The solid residue was dissolved in 40 ml of hot 95% methanol and the resulting solution was filtered and reduced in volume to about 10 ml. After cooling, the crystals were filtered and washed with ethanol and ether to yield about 100 mg of 2-deoxy-L-fucopyranosyl carminomycinone (IV) having a melting point of 228°-232° C. Elemental analysis of the material gave the following results:
Calculated weight percent for C 26 H 26 O 11 , 0.5 H 2 O: C=59.65, H=5.20. Found: C=59, H=4.91.
The structure for the glycoside (IV) was confirmed by its n.m.r. spectrum.
EXAMPLE 2
Bilogical Activity
The carminomycinone glycoside prepared by the procedure described in Example 1 was tested against transplanted mouse leukemia L 1210 according to the procedures described in Cancer Chemother, Rep., 3:1-87, Part 3 (1972). Two experiments were conducted. The mice were given a single treatment in the first experiment and the mice were given both a single treatment and a daily injection for 9 days (QD 1→9) in the second experiment.
The test results are summarized in Table I. From these data, it can be seen that the survival time of tumor bearing animals was increased 86% over the control in the first experiment and at least one dose for each type of treatment in the second experiment increased the survival time by 71%.
From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of the invention, and without departing from the spirit and scope thereof, can make various changes and modifications to adapt it to various usages. | A novel anthracycline glycoside 2-deoxy-L-fucopyranosyl carminomycinone which is effective for inhibiting the growth of tumors such as leukemia L1210. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to improvements in a suction controller for an endoscope which is capable of performing an air supply, water supply or a procedure for inserting operation instruments such as forceps in addition to a suction procedure by way of a channel of the endoscope.
Such a suction controller has been heretofore constructed as shown in FIG. 1. Specifically, a guide tube 5 comprises a first lower tube 3 and a second lower tube 4 both of which are threadedly connected to each other end to end. The guide tube 5 is disposed within an outer tube 1 in such a manner that a space portion 6 is formed between the guide tube 5 and the outer tube 1. A suction tube 2 is connected to the peripheral wall of the outer tube 1 whose lower end is connected to a channel of an endoscope. A slide tube 7 is inserted in the guide tube 5 and is resiliently held by a spring 8 which is interposed between the outer peripheral surface of the slide tube 7 and the inner peripheral surface of the guide tube 5. A support tube 10 is provided through a connecting tube 9 at the lower end of the slide tube 7. A slider 12 having a through-hole 11 through which an operation instrument passes is held by the support tube 10. A communicating hole 13 through which the space portion 6 communicates with the interior of the guide tube 5 is provided through the peripheral wall of the first tube 3. A cap 14 is mounted on the upper end of the outer tube 1. The cap 14 has a holding hole 15 through which the upper end of the guide tube 5 communicates with the exterior and an air hole 16 through which the space portion 6 communicates with the open air.
With the above-noted arrangement, suction of mucus or filth in a coeliac cavity can be effected by blocking the holding hole 15 and the air hole 16 with a finger. When both holes 15 and 16 are blocked, the suction path previously extending from air hole 16 to space portion 6 to the suction tube 2 is now changed to extend through the channel on the coeliac cavity as shown with an arrow a in FIG. 1, so that mucus or filth in the coeliac cavity can be drawn into the suction tube 2. An operation procedure using an operation instrument and a suction procedure can be simultaneously effected by inserting the operation instrument through the slide tube 7 and the through-hole 11 of the slider 12 into the channel and simultaneously blocking the air hole 16 with a finger. Furthermore, a liquid supply procedure can be effected by fitting the tip end of an injector into the slide tube 7 and slidingly pushing the slide tube 7 against the restoring force of the spring 8 to block the communicating hole 13 by the support tube 10 which shifts together with the slide tube 7. Accordingly, the interior of the guide tube 5 is shut off from the space portion 6 so that liquid can be fed from the injector through the channel into a coeliac cavity.
However, according to the conventional arrangement described above, since the support tube 10 which blocks the communicating hole 13 during the liquid supply procedure is slidingly fitted into the guide tube 5, it is impossible to seal the sliding plane of the support tube 10 in a reliable manner. Accordingly, a part of liquid ejected from an injector is drawn in the suction tube 2 through the space portion 6 and thus there is a possibility that the liquid may not be completely fed into a coeliac cavity.
SUMMARY OF THE INVENTION
In view of the foregoing, it is an object of the present invention to provide a suction controller for an endoscope which is capable of reliably blocking the path between a channel of the endoscope and a suction tube during a liquid supply procedure.
According to the present invention, a valve member formed of resilient material is provided on a shiftable tube which is guided by a guide tube and is pushed against a valve seat during a liquid supply procedure so as to block the path between the channel of the endoscope and the suction tube in a reliable manner. Accordingly, during the liquid supply procedure, liquid does not enter into the suction tube and the shiftable tube is guided by the guide tube, thereby, assuring reliable functions of the suction controller.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an enlarged sectional view illustrating an example of a conventional suction controller;
FIG. 2 is a perspective view of an endoscope provided with a suction controller according to the present invention;
FIG. 3 is an enlarged sectional view of an embodiment of a suction controller according to the present invention;
FIG. 4 is a sectional view illustrating the suction controller shown in FIG. 3 which is in a suction procedure;
FIG. 5 is a sectional view illustrating the suction controller shown in FIG. 3 which is in a procedure for inserting a forceps;
FIG. 6 is a sectional view illustrating the suction controller shown in FIG. 3 which is in a liquid supply procedure;
FIG. 7 is an enlarged sectional view illustrating another embodiment of a suction controller according to the present invention; and
FIG. 8 is a sectional view illustrating the suction controller shown in FIG. 7 which is in a liquid supply procedure.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 2, an endoscope 20 comprises an operating portion 21 and an inserting portion 22. The operating portion 21 includes an eyepiece portion 23, an operating knob 24 for bending the distal end portion of the insertion portion 22, a light guide cable 25 which is connected to a light source (not shown) and a suction controller 26. Details of the arrangement of the suction controller 26 are shown in FIG. 3. The suction controller 26 has a support tube 27 which is secured to the operating portion 21. The support tube 27 communicates with a channel 28 of the endoscope. The channel 28 extends over an overall length of the operating portion 21 and the inserting portion 22. The front end (lower end in the figure) of the channel 28 opens at the distal end of the inserting portion 22 (see FIG. 2). A flange-shaped cap holder 29 is formed at the back end (upper end in the figure) of the support tube 27. (It is to be noted that the words "front (lower)" and "back (upper)" as used herein indicate the inserting portion side and the operating portion side of the endoscope, respectively.) A cap 31 which is formed of comparatively hard and resilient material such as fluorine rubber, silicone rubber, nitrile rubber (NBR) and urethane rubber is hermetically and detachably mounted on the cap holder 29. The cap 31 has a holding hole 32 and an air hole 33 which pass through the wall thereof. The holding hole 32 is located on an extension of the center axis of the support tube 27 and the air hole 33 is located out of the center axis of the support tube 27. A holding ring 35 to which the upper end of a guide tube 34 is threadedly secured is fitted and held in the holding hole 32. The holding ring 35 has a tapered plane 36 formed in the inner periphery thereof for fitting an injector, as will be described later. A plurality of first support pieces 37 and a plurality of second support pieces 38 are arranged respectively on the outer periphery of the guide tube 34 spacedly in its axial direction and along the peripheral direction of the guide tube 34. The first support 37 engages a step which is formed on the inner periphery of the back end portion of the support tube 27 so that the support tube 27 is not further pushed back. The second support piece 38 prevents swing of the guide tube 34 in abutment with the inner peripheral surface of the intermediate portion of the support tube 27.
A slide tube 41 is slidably fitted in the guide tube 34 as a shiftable tube and is resiliently urged backwardly by a spring 42 which is interposed between the outer peripheral surface of the slide tube 41 and the inner peripheral surface of the guide tube 34. Normally, slide tube 41 is located in the position as shown in FIG. 3, wherein a collar 43 projectedly provided on the outer periphery of the slide tube 41 abuts against the holding ring 35. In addition, under the normal condition, the front end portion of the slide tube 41 projects forwardly in the longitudinal direction from the guide tube 34. Also, a valve member fixing portion 45 on which a valve member 44 is mounted is formed on the outer periphery of the projected front end portion of the slide tube 41. The valve member 44 is a substantially pillar-shaped member made of resilient material such as fluorine rubber, silicone rubber, NBR and urethane rubber in which a spherical hollow portion 46 is formed, and has an opening 47 at the upper end thereof which is attached to the valve member fixing portion 45. A comparatively small through-hole 48 is formed on the front end of the valve member 44 so as to allow an operation instrument such as a forceps 49, to pass therethrough closely (see FIG. 5).
The valve member 44 under the normal condition shown in FIG. 3 faces a valve seat 51 apart therefrom, which seat is formed in a tapered form on the inner wall of the support tube 27. When the slide tube 41 is pushed down, the valve member 44 bears against the valve seat 51 so that the path between a space portion 52 formed between the outer peripheral surface of the guide tube 34 and the inner peripheral surface of the support tube 27 and the channel 28 is blocked (see FIG. 6). A suction tube 53 has its one end connected to the side wall of the support tube 27 and communicates with the space portion 52. The other end of the suction tube 53 is connected through a flexible tube 54 to a suction apparatus 55, as shown in FIG. 2.
In operation, when the suction apparatus 55 is operated under the normal condition shown in FIG. 3, the suction force is exerted through the flexible tube 54 and the suction tube 53 on the space portion 52. At this time, since the air hole 33 is open to the atmosphere, air is drawn through the air hole 33 into the space portion 52 and accordingly the suction force is not exerted through the channel 28 on a coeliac cavity.
When mucus or filth is to be drawn, both the holding hole 32 and the air hole 33 which have been open to the exterior are now blocked by covering the whole upper surface of the cap 31 with a finger, as shown in FIG. 4, whereby the communication between the space portion 52 and the exterior is broken and the suction force is exerted through the suction tube 53 on the channel 28. As a result, mucus or filth in the coeliac cavity is drawn from the channel 28 through the space portion 52 in the suction tube 53.
When a forceps 49 is to be used, it is inserted from the upper end opening of the slide tube 41 through the holding hole 32, as shown in FIG. 5, and is guided through the hollow portion 46 of the valve member 44 and the through-hole 48 to the channel 28. Under this condition, since the through-hole 48 becomes in air tightness with the forceps 49 closely fitted thereinto, there is no likelihood that the space portion 52 communicates through the slide tube 41 with the exterior. Further, since the suction tube 53 communicates through the space portion 52 and the air hole 33 with the atmosphere to draw air, there is no likelihood that the suction force is exerted on the channel 28.
When the suction procedure is effected while the forceps 49 is in use, the air hole 33 in the cap 31 is covered with a finger, as shown in FIG. 5, whereby the communication between the space portion 52 and the atmosphere is broken and mucus or filth in a coeliac cavity can be drawn accordingly by suction.
When liquid such as a liquid medicine is to be fed through the channel 28, a tapered tip end 57 of an injector 56 is fitted into the tapered inner peripheral surface 36 of the holding ring 35, as shown in FIG. 6. The slide tube 41 is slidingly pushed in against the resilient force of the spring 42 by applying a pushing force to the injector 56 to press the valve member 44 against the valve seat 51 with the result of resilient deformation of the valve member 44, whereby the communication between the space portion 52 and the channel 28 is broken and the space portion 52 communicates through the air hole 33 with the atmosphere to draw air. While this condition is maintained, the liquid is ejected by operating the injector 56. The liquid is not drawn in the suction tube 53 but is reliably fed through the channel 28 into the coeliac cavity.
In FIG. 7, which illustrates a second embodiment of the present invention, a thin wall cylinder-shaped expandable portion 61 is connected with the valve member 44 in place of the spring 42 which urges the slide tube 41 in the first embodiment. Specifically, a lock 62 is formed on the lower end outer periphery of the guide tube 34 and the upper end of the expandable portion 61 is attached to the lock 62. This structure can be used in a manner similar to the first embodiment. When liquid such as a liquid medicine is to be injected with an injector 56, the tapered tip end 57 of the injector 56 is held by pushing it into the tapered inner peripheral surface 36 of the holding ring 35 and the expandable portion 61 is then stretched, as shown in FIG. 8. Thus, the same action as the spring 42 in the first embodiment is attained.
Furthermore, it is to be noted that in the second embodiment, a cylindrical packing 63 made of rubber is provided on the upper end of the slide tube 41 so that liquid tightness between the packing 63 and the tapered tip end 57 of the injector 56 can be secured by pressing the tapered tip end 57 against the packing 63. | A suction controller of an endoscope is provided with a valve member made of resilient material on a shiftable tube which is guided by a guide tube disposed within a support tube so that when liquid is fed said valve member is pressed against a valve seat disposed on said support tube with said shiftable tube shifted to break the communication between a suction tube and a channel of the endoscope. As a result, the liquid is no longer drawn into the suction tube during the liquid feeding and the shifting of the shiftable tube is guided by the guide tube, so that the reliable functions of the suction controller can be assured. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to a process for preparing frozen whipped topping compositions. More particularly, it relates to a process for preparing frozen whipped topping compositions containing real cream and which have extended refrigerator shelf life after thawing. This composition is suitable for use as a whipped cream substitute and as a topping for desserts, icing for cakes and the like. Frozen whipped toppings based upon miik fat (i.e., containing real cream) have previously had a very short shelf life or poor eating qualities after thawing. These prior art samples became loose, soupy (soft, no resilience), open textured (grainy, webby) and exuded free liquid within hours after thawing in the refrigerator. Freeze-thaw stability could previously only be obtained by giving the product a heavy, thick mouthfeel, uncharacteristic of freshly whipped cream and even then the refrigerator stability was limited (i.e. 2 to 3 days). The present invention extends the refrigerator shelf life of the topping based upon milk fat for a period up to as much as 5 to 7 days or longer while maintaining the mouthfeel, texture and appearance characteristic of freshly whipped cream and represents a significant advance over that which had been available in the art.
The prior art reveals many attempts at stabilizing whipped toppings by use of stabilizers such as starches, emulsifiers, or gums, but many of these systems are directed to dry mixes or concentrates and not to frozen whipped toppings based upon milk fat, much less a topping with extended refrigerator shelf life and improved mouthfeel, texture and appearance characteristics after thawing. U.S. Pat. No. 3,431,117 by Lorant does prepare a stable frozen whipped topping, however, the specific problem of stabilizing a milk fat system is not dealt with nor is the specific stabilizer critical to the present invention disclosed.
Therefore, it is a feature of the present invention to provide an improved frozen whipped topping composition.
A further feature of the present invention is to provide a process for preparing a frozen whipped topping composition based upon milk fat, which composition has extended refrigerator shelf life after thawing.
A still further feature of the present invention is to provide a whipped topping composition which upon thawing, has the attributes of freshly prepared whipped cream.
SUMMARY OF THE INVENTION
Briefly, the instant invention provides a process for preparing a frozen whipped topping based upon milk fat and having improved stability upon thawing and refrigerator storage comprising blending milk fat, emulsifiers, stabilizers, carbohydrate, water and a modified starch, pasteurizing and homogenizing these ingredients to form an emulsion, cooling the emulsion, whipping the emulsion, and then freezing the emulsion. The modified starch employed is a cross-linked and hydroxypropylated starch. The frozen whipped topping so prepared upon thawing is characterized by its excellent volume, texture and eating properties, the superior storage stability after thawing, as well as the convenience offered to the consumer.
DETAILED DESCRIPTION OF THE INVENTION
The process of the present invention makes it possible to prepare a frozen whipped topping composition containing real cream which may be distributed and sold in a frozen state and which upon thawing retains its excellent volume, smooth, continuous, light and fluffy texture, and eating properties for an extended period of time. The thawed composition may be stored at refrigeration temperatures for a period of about 5 to 7 days or longer without an apparent loss in volume, texture and eating properties. Thus, the composition may be described as having exceptional freeze-thaw stability as well as extended stability upon thawing at refrigerated temperatures.
The unique and surprising characteristic of the present invention is the ability to employ real cream, i.e. milk fat, in the preparation of a frozen whipped topping which is stable upon thawing. The fat employed is a milk fat, such as that derived from real cream, butter fat, anhydrous milk fat or other milk fat sources. By the use of milk fat, the resultant topping imparts a fast meltdown in the mouth, thus providing a mouthfeel close to freshly prepared whipped cream.
Critical to stabilizing milk fat in the frozen whipped topping of the present invention is employing a modified starch to stabilize the emulsion and provide the freeze-thaw capabilities while withstanding homogenization and high temperatures during processing of the topping. The specified modified starch is critical in that other starches or gums have not been found to impart the requisite freeze-thaw and refrigerator shelf life stability or impart the desired volume, texture and eating qualities to the frozen whipped topping composition. The starch is modified by cross-linking and hydroxypropylation with a cross-linked and hydroxypropylated tapioca starch providing the optimum stability and characteristics upon thawing the frozen whipped topping although other cross-linked and hydroxypropylated starches, such as waxy maize starch, are also suitable.
The starch is hydroxypropylated, e.g. with propylene oxide, to preferably a level of at least about 0.2% with a preferred upper limit of 6%, by weight of hydroxypropyl groups by weight of the starch. The degree of hydroxypropylation is determined by standard analytic techniques such as that described by Stahl and McNaught, in Cereal Chemistry (Vol 47, No. 4, 1970, 345-350). The degree a starch is cross-linked is standardly determined by reference to the viscosity characteristics of the modified starch over time and temperature, i.e. by viscometric analysis using an instrument such as the Brabender Viscoamylograph (C.W. Brabender Instruments Inc., South Hackensach, N.J.). Analysis with the Brabender Viscoamylograph is widely used in the starch industry as is discussed in the following literature: Starch Production Technology by J. A. Radley, (Applied Science Pub., Ltd, 1976); The Chemistry of Wheat Starch and Gluten by J. W. Knight (Leonard Hill, 1965, pages 135-137); and American Association of Cereal Chemists (approved methods of the AACC, Method No. 22-10). As measured on a Brabender Viscoamylograph the cross-linked and hydroxypropylated starch of the instant invention should have a viscosity of about 80 to 500 units at 95° C. and after 10 minute hold at 95° C. the increase in viscosity should be within the range of about 0-100 units. Preferably, the cross-linked and hydroxypropylated starch has a viscosity of about 150 to 350 Brabender Units at 95° C. The following conditions were employed in the analysis of the starch with the Brabender Viscoamylgraph: 700 CM GMS cartridge; 75 r.p.m.; 30 grams starch (dry basis) in a total charge weight of 500 grams; initial temperature of 30° C. with a heating rate increase of 1.5° C. per minute; and maximum temperature of 95° C. with a hold at that temperature for 10 minutes.
The cross-linked and hydroxypropylated starch may be prepared by, for example, suspending 2 kilograms of tapioca starch in 3 liters of water containing 750 grams of sodium sulfate adjusted to a pH of 11. Propylene oxide (hydroxypropylation agent) at a level of 400 ml was added and the suspension stirred at room temperature for 20 hours. Phosphorous oxychloride (cross-linking agent) at a level of 0.024 ml was then added and the suspension stirred for an additional two hours. The modified starch was then filtered, washed thoroughly with water and air dried to 10% moisture. The resultant modified starch had a hydroxypropyl content of 0.4% and as measured on a Brabender Viscoaymlograph had a viscosity of 180 units at 95° C. and a 60 unit increase during the 10 minute hold at 95° C. The modified tapioca starch is preferably employed in the frozen whipped topping of the present invention at a level of 0.05 to 1.0% by weight of the composition, and optimally at levels within the range of about 0.25 to 0.5% by weight of the composition.
A wide variety of emulsifiers may be employed in the compositions which are prepared by the process of this invention. Thus, the following emulsufiers may all be used: hydroxylated lecithin; mono- or di-glycerides of fatty acids such as monostearin and dipalmitin; polyoxyalkylene ethers of fatty esters of polyhydric alcohols such as the polyoxyethylene ethers or sorbitan monostearate or the polyoxyethylene ethers of sorbitan distearate; fatty esters of polyhydric alcohols, such as sorbitan monosteareate; mono- and di-esters of glycols and fatty acids such as propylene glycol monostearate and propylene glycol monopalmitate; and partial esters of carboxylic acids such as lactic, citric and tartaric acids with the mono- and di-glycerides of fatty acids such as glyceryl lactopalmitate and glyceryl lactooleate. The fatty acids employed in the preparation of the emulsifiers include those derived from beef tallow, coconut, cotton-seed, palm, peanut, soybean, marine oils etc. The preferred emulsifiers employed in the composition of the present invention to impart optimum stability, appearance and textural attributes are polyglycerol esters (e.g. hexa-glycerol di-stearate) and tartaric acid esters, generally at levels ranging from 0.1 to 0.3% by weight of the composition. Preferably, a combination of emulsifiers is employed, typically polyoxyethylene sorbitan monostearate (Polysorbate 60) and sorbitan monostearate.
A stabilizer is also desirably included in the frozen whipped topping composition. Such stabilizer is preferably a natural, i.e. vegetable, or synthetic gum and may be, for example, carrageenan, guar gum, alginate, xanthan gum, and the like or carboxymethylcellulose, methylcellulose and the like, and mixtures thereof.
A carbohydrate is employed in the frozen whipped topping composition to provide bulk and the desired sweetness. Thus, sugars such as sucrose, dextrose, fructose, lactose, maltose, invert sugars and mixtures thereof may be utilized as well as dextrins and low calorie sweeteners such as L-aspartic acid derivatives and saccharin.
Other ingredients which may be included in the frozen whipped topping compositions prepared by the process of this invention are flavoring agents, colorants or dyes, vitamins, minerals, and the like. Suitable flavoring agents include vanilla, chocolate, coffee, maple, spice, mint, caramel, fruit flavors and flavor intensifiers (e.g. salt).
The amounts of milk fat, emulsifier, stabilizer, carbohydrate, and optionally included ingredients as well as the amount of water employed in the preparation of frozen whipped topping compositions according to the process of this invention can be varied over relatively wide limits. When homogenization of the composition using a pressure of at least 6000 p.s.i. (420 kg/cm 2 ) is employed, this allows considerable latitude in the amounts of the various ingredients. The amount of milk fat will be sufficient to provide a stable whipped topping which has good mouthfeel and yet, upon melting, does not leave an undesirable film on the palate. Sufficient amounts of modified starch, emulsifier, and stabilizer will be used to impart stability to the topping and to impart good whipping properties to the composition. Further, the amount of carbohydrate will be varied over a range sufficient to provide desired bulk and sweetness level in the finished topping composition. A preferred range of ingredients is as follows:
______________________________________Ingredients Percent by weight______________________________________Milk Fat (solids basis) 15.0-30.0Modified Tapioca Starch 0.2-1.0Emulsifier 0.2-2.0Stabilizer (gum) 0.02-2.0Water 35.0-65.0Carbohydrate (sugar) 15.0-35.0Flavoring Agent 0.2-2.0Colorant 0.01-0.05______________________________________
The ingredients are blended in suitably desirable ratios to form a mix. The mix may then be heat pasteurized, i.e. subject to a sufficiently high temperature for a period of time effective to solubilize and disperse the ingredients of the mix, gelatinize the starch and kill all pathogens, e.g. at a temperature of about 155° F. (70° C.) to 165° F. (75° C.), for about 30 minutes, or similar time-temperature relationships (e.g. high-temperature short time). The mix is then passed through a homogenizer of the typical dairy type. Although homogenization may be accomplished in one stage, for best results, homogenization is carried out in two stages, operated with the pressure maintained during the first stage preferrably at a minimum of 6000 p.s.i. (420 Kg/cm 2 ) and a maximum of about 10,000 p.s.i. (700 Kg/cm 2 ), preferably about 7500 p.s.i. (525 Kg/cm 2 ), and the second stage at a pressure of at least about 500 p.s.i. (35 Kg/cm 2 ). The mix temperature is usually maintained at a temperature of about 155° F. (70° C.) to 180° F. (80° C.) during homogenization. The emulsion is then cooled, e.g. to about 27° F. (-3° C.) to 45° F. (7° C.) and may be held at this temperature for a period of time sufficient to allow fat crystallization. The emulsion is then passed through a whipper for the incorporation of air or an inert gas such as nitrogen, carbon dioxide, nitrous oxide or the like. The whipper may be of conventional construction such as a Votator Continuous Recirculating Mixer (Trademark). The emulsion is whipped and aerated to above 200% overrun, preferably above about 250% overrun, packaged and frozen.
The process of the present invention thus produces a real cream frozen whipped topping composition which is stable and remains smooth after several freeze-thaw cycles. The frozen topping composition upon thawing has a prolonged refrigeration shelf life, while possessing the light, fluffy, smooth and continuous texture, mouthfeel, appearance, volume and eating quality characteristic of freshly prepared whipped cream. To use the frozen whipped topping composition, the product is defrosted, for example, by being left for 31/2 hours (for a 4.5 ounce or 125 gram container) in the refrigerator. The composition after thawing is thus ready for immediate table use without the necessity of reconstitution or whipping.
In order to illustrate the present invention, but in no matter to restrict it, the following example is given
EXAMPLE
The frozen topping composition was prepared containing the following ingredients:
______________________________________ Percent by Weight______________________________________Heavy Cream (40% fat) 62.5Sugar 20.5Water 14.4Dextrose 1.2Crosslinked and HydroxypropylatedTapioca Starch .5Polysorbate 60 .3Sorbitan Monostearate .2Flavor .2Xanthan Gum .1Guar Gum .1 100.0%______________________________________
The tapioca starch had a hydroxypropyl content of 0.4% and at 95° C. a viscosity of 180 units and a 60 unit increase during the 10 minute hold at 95° C., as measured on a Brabender Viscoamylograph having a 700 CM GMS cartridge, operated at 75 r.p.m., with 30 grams of dry starch in a total charge weight of 500 grams. The ingredients were mixed together and then pasteurized at 160° F. (70° C.) for 30 minutes. The pasteurized mix is then homogenized in two stages to form the emulsion. The first stage homogenization employing pressures of about 7200 p.s.i (500 Kg/cm 2 ) and the second stage employing pressures of 800 p.s.i. (55 Kg/cm 2 ). The homogenized mix is then cooled for 20 minutes at a temperature of 32° F. (0° C.) to 36° F. (2° C.) to allow fat crystallization. The cooled mix is then whipped and aerated in a Votator C. R. Mixer (Trademark) to above 200% overrun. The whipped mix is then packaged and frozen.
The composition so prepared is characterized by its excellent freeze-thaw stability even after several freeze-thaw cycles. After thawing and storage at refrigerator temperatures (about 40° F., 5° C.) for 5 days and longer the texture remained light, fluffy, continuous and smooth and did not become loose, soupy (no resilience), open textured (grainy, webby), or exude free liquid. Over the five days of refrigeration storage the thawed topping composition maintained a mouthfeel, texture, volume, appearance and eating quality characteristic of freshly prepared whipped cream. | A process is provided for preparing a frozen whipped topping composition containing milk fat, which upon thawing, has an extended refrigerator shelf life while maintaining its volume, texture and eating properties. The process involves blending milk fat, emulsifier, stabilizer, carbohydrate and water with a cross-linked and hydroxypropylated starch, followed by pasteurizing, homogenizing, cooling, whipping and freezing the composition. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a Division of application Ser. No. 13/212,274 filed Aug. 18, 2011, which is a Division of application Ser. No. 10/351,664 filed Jan. 27, 2003, which claims the benefit of U.S. Provisional Application 60/373,404 filed Apr. 8, 2002, the entire contents of all of which are hereby incorporated herein by reference.
TECHNICAL FIELD
The systems, methods, application programming interfaces (API), graphical user interfaces (GUI), computer readable media, and so on described herein relate generally to controllers and more particularly to scaling and parameterizing controllers, which facilitates improving controller design, tuning, and optimizing.
BACKGROUND
A feedback (closed-loop) control system 100 , as shown in Prior Art FIG. 1 , is widely used to modify the behavior of a physical process, denoted as the plant 110 , so it behaves in a specific desirable way over time. For example, it may be desirable to maintain the speed of a car on a highway as close as possible to 60 miles per hour in spite of possible hills or adverse wind; or it may be desirable to have an aircraft follow a desired altitude, heading and velocity profile independently of wind gusts; or it may be desirable to have the temperature and pressure in a reactor vessel in a chemical process plant maintained at desired levels. All these are being accomplished today by using feedback control, and the above are examples of what automatic control systems are designed to do, without human intervention.
The key component in a feedback control system is the controller 120 , which determines the difference between the output of the plant 110 , (e.g., the temperature) and its desired value and produces a corresponding control signal u (e.g., turning a heater on or off). The goal of controller design is usually to make this difference as small as possible as soon as possible. Today, controllers are employed in a large number of industrial control applications and in areas like robotics, aeronautics, astronautics, motors, motion control, thermal control, and so on.
Classic Controllers:
Classic Control Theory provides a number of techniques an engineer can use in controller design. Existing controllers for linear, time invariant, and single-input single output plants can be categorized into three forms: the proportional/integral/derivative (PID) controllers, transfer function based (TFB) controllers, and state feedback (SF) controllers. The PID controller is defined by the equation
u=K P e+K I ∫e+K D ė (1)
where u is the control signal and e is the error between the setpoint and the process output being controlled. This type of controller has been employed in engineering and other applications since the early 1920s. It is an error based controller that does not require an explicit mathematical model of the plant. The TFB controller is given in the form of
U ( s ) = G c ( s ) E ( s ) , G c ( s ) = n ( s ) d ( s ) ( 2 )
where U(s) and E(s) are Laplace Transforms of u and e defined above, and n(s) and d(s) are polynomials in s. The TFB controller can be designed using methods in control theory based on the transfer function model of the plant, G p (s). A PID controller can be considered a special case of a TFB controller because it has an equivalent transfer function of
G c ( s ) = k p + k i s + k d s ( 3 )
The State Feedback (SF) Controller
The SF controller can be defined by
u=r+K{circumflex over (x)} (4)
and is based on the state space model of the plant:
{dot over (x)} ( t )= Ax ( t )+ Bu ( t ), y ( t )= Cx ( t )+ Du ( t ) (5)
When the state x is not accessible, a state observer (SO):
{dot over (x)}=A{circumflex over (x)}+Bu+L ( y−ŷ ) (6)
is often used to find its estimate, {circumflex over (x)}. Here r is the setpoint for the output to follow.
In addition to the above controllers, a more practical controller is the recently developed Active Disturbance Rejection Controller (ADRC). Its linear form (LADRC) for a second order plant is introduced below as an illustration. The unique distinction of ADRC is that it is largely independent of the mathematical model of the plant and is therefore better than most controllers in performance and robustness in practical applications.
Linear Activated Disturbance Rejection Controller (LADRC)
Consider an example of controlling a second order plant
ÿ=−a{dot over (y)}−by+w+bu (7)
where y and u are output and input, respectively, and w is an input disturbance. Here both parameters, a and b, are unknown, although there is some knowledge of b, (e.g., b 0 ≈b, derived from the initial acceleration of y in step response). Rewrite (7) as
ÿ=−a{dot over (y)}−by+w +( b−b 0 ) u+b 0 u=ƒ+b 0 u (8)
where ƒ=−a{dot over (y)}−by+w+(b−b 0 )u. Here ƒ is referred to as the generalized disturbance, or disturbance, because it represents both the unknown internal dynamics, −a{dot over (y)}−by+(b−b 0 )u and the external disturbance w(t).
If an estimate of ƒ, {circumflex over (ƒ)} can be obtained, then the control law
u = - f ^ + u 0 b 0
reduces the plant to ÿ=(ƒ−{circumflex over (ƒ)})+u 0 , which is a unit-gain double integrator control problem with a disturbance (ƒ−{circumflex over (ƒ)}).
Thus, rewrite the plant in (8) in state space form as
{ x . 1 = x 2 x . 2 = x 3 + b 0 u x . 3 = h y = x 1 ( 9 )
with x 3 =ƒ added as an augmented state, and h={dot over (ƒ)} is seen as an unknown disturbance. Now ƒ can be estimated using a state observer based on the state space model
{dot over (x)}=Ax+Bu+Eh
y=Cz (10)
where
A = [ 0 1 0 0 0 1 0 0 0 ] , B = [ 0 b 0 0 ] , C = [ 1 0 0 ] , E = [ 0 0 1 ]
Now the state space observer, denoted as the linear extended state observer (LESO), of (10) can be constructed as
ż=Az+Bu+L ( y−ŷ )
ŷ=Cz (11)
which can be reconstructed in software, for example, and L is the observer gain vector, which can be obtained using various methods known in the art like pole placement,
L=[β 1 β 2 β 3 ] T (12)
where [ ] T denotes transpose. With the given state observer, the control law can be given as:
u = - z 3 + u 0 b 0 ( 13 )
Ignoring the inaccuracy of the observer,
ÿ= (ƒ− z 3 )+ u 0 ≈u 0 (14)
which is an unit gain double integrator that can be implemented with a PD controller
u 0 =k p ( r−z 1 )− k d z 2 (15)
Controller Tuning
Over the years, the advances in control theory provided a number of useful analysis and design tools. As a result, controller design moved from empirical methods (e.g., ad hoc tuning via Ziegler and Nichols tuning tables for PID) to analytical methods (e.g., pole placement). The frequency response method (Bode and Nyquist plots) also facilitated analytical control design.
Conventionally, controllers are individually designed according to design criteria and then individually tuned until they exhibit an acceptable performance. Practicing engineers may design controllers, (e.g., PID) using look-up tables and then tune the controllers using trial and error techniques. But each controller is typically individually designed, tuned, and tested.
Tuning controllers has perplexed engineers. Controllers that are developed based on a mathematical model of the plant usually need their parameters to be adjusted, or “tuned” as they are implemented in hardware and tested. This is because the mathematical model often does not accurately reflect the dynamics of the plant. Determining appropriate control parameters under such circumstances is often problematic, leading to control solutions that are functional but ill-tuned, yielding lost performance and wasted control energy. Additionally, and/or alternatively, engineers design using analytical (e.g., pole placement) techniques, but once again tune with trial and error techniques. Since many industrial machines and engineering applications are built to be inherently stable, acceptable controllers can be designed and tuned using these conventional techniques, however, acceptable performance may not approach optimal performance.
One example conventional technique for designing a PID controller included obtaining an open-loop response and determining what, if anything, needed to be improved. By way of illustration, the designer would build a candidate system with a feedback loop, guess the initial values of the three gains (e.g., k p , k d , k i ) in PID and observe the performance in terms of rise time, steady state error and so on. Then, the designer might modify the proportional gain to improve rise time. Similarly, the designer might add or modify a derivative controller to improve overshoot and an integral controller to eliminate steady state error. Each component would have its own gain that would be individually tuned. Thus, conventional designers often faced choosing three components in a PID controller and individually tuning each component. Furthermore, there could be many more parameters that the design engineer must tune if a TFB or a state feedback state observer (SFSOB) controller is employed.
Another observation of control design is that it is not portable. That is, each control problem is solved individually and its solution cannot be easily modified for another control problem. This means that the tedious design and tuning process must be repeated for each control problem.
Thus, having reviewed controllers, the application now describes example systems and methods related to controllers.
SUMMARY
This section presents a simplified summary of methods, systems, computer readable media and so on for scaling and parameterizing controllers to facilitate providing a basic understanding of these items. This summary is not an extensive overview and is not intended to identify key or critical elements of the methods, systems, computer readable media, and so on or to delineate the scope of these items. This summary provides a conceptual introduction in a simplified form as a prelude to the more detailed description that is presented later.
The application describes scaling and parameterizing controllers. With these two techniques, controller designing, tuning, and optimizing can be improved. In one example, systems, methods, and so on described herein facilitate reusing a controller design by scaling a controller from one application to another. This scaling may be available, for example, for applications whose plant differences can be detailed through frequency scale and/or gain scale. While PID controllers are used as examples, it is to be appreciated that other controllers can benefit from scaling and parameterizing as described herein.
Those familiar with filter design understand that filters may be designed and then scaled for use in analogous applications. Filter designers are versed in the concept of the unit filter which facilitates scaling filters. In example controller scaling techniques, a plant transfer function is first reduced to a unit gain and unit bandwidth (UGUB) form. Then, a known controller for an appropriate UGUB plant is scaled for an analogous plant. Since certain plants share certain characteristics, classes of UGUB plants can be designed for which corresponding classes of scaleable, parameterizable controllers can be designed.
Since certain classes of plants have similar properties, it is possible to frequency scale controllers within classes. For example, an anti-lock brake plant for a passenger car that weighs 2000 pounds may share a number of characteristics with an anti-lock brake plant for a passenger car that weighs 2500 pounds. Thus, if a UGUB plant can be designed for this class of cars, then a frequency scaleable controller can also be designed for the class of plants. Then, once a controller has been selected and engineered for a member of the class (e.g., the 2000 pound car), it becomes a known controller from which other analogous controllers can be designed for other similar cars (e.g., the 2500 pound car) using frequency scaling.
This scaling method makes a controller “portable”. That is a single controller can be used as the “seed” to generate controllers for a large number of different plants that are similar in nature. The remaining question concerns how to account for differences in design requirements. Controller parameterization addresses this issue. The example parameterization techniques described herein make controller coefficients functions of a single design parameter, namely the crossover frequency (also known as the bandwidth). In doing so, the controller can be tuned for different design requirements, which is primarily reflected in the bandwidth requirement.
The combination of scaling and parameterization methods means that an existing controller (including PID, TFB, and SFSOB) can be scaled for different plants and then, through the adjustment of one parameter, changed to meet different performance requirements that are unique in different applications.
Certain illustrative example methods, systems, computer readable media and so on are described herein in connection with the following description and the annexed drawings. These examples are indicative, however, of but a few of the various ways in which the principles of the methods, systems, computer readable media and so on may be employed and thus are intended to be inclusive of equivalents. Other advantages and novel features may become apparent from the following detailed description when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Prior Art FIG. 1 illustrates the configuration of an output feedback control system.
FIG. 2 illustrates a feedback control configuration.
FIG. 3 illustrates an example controller production system.
FIG. 4 illustrates an example controller scaling method.
FIG. 5 illustrates an example controller scaling method.
FIG. 6 compares controller responses.
FIG. 7 illustrates loop shaping.
FIG. 8 illustrates a closed loop simulator setup.
FIG. 9 compares step responses.
FIG. 10 illustrates transient profile effects.
FIG. 11 compares PD and LADRC controllers.
FIG. 12 illustrates LESO performance.
FIG. 13 is a flowchart of an example design method.
FIG. 14 is a schematic block diagram of an example computing environment.
FIG. 15 illustrates a data packet.
FIG. 16 illustrates sub-fields within a data packet.
FIG. 17 illustrates an API.
FIG. 18 illustrates an example observer based system.
LEXICON
As used in this application, the term “computer component” refers to a computer-related entity, either hardware, firmware, software, a combination thereof, or software in execution. For example, a computer component can be, but is not limited to being, a process running on a processor, a processor, an object, an executable, a thread of execution, a program and a computer. By way of illustration, both an application running on a server and the server can be computer components. One or more computer components can reside within a process and/or thread of execution and a computer component can be localized on one computer and/or distributed between two or more computers.
“Computer communications”, as used herein, refers to a communication between two or more computers and can be, for example, a network transfer, a file transfer, an applet transfer, an email, a hypertext transfer protocol (HTTP) message, a datagram, an object transfer, a binary large object (BLOB) transfer, and so on. A computer communication can occur across, for example, a wireless system (e.g., IEEE 802.11), an Ethernet system (e.g., IEEE 802.3), a token ring system (e.g., IEEE 802.5), a local area network (LAN), a wide area network (WAN), a point-to-point system, a circuit switching system, a packet switching system, and so on.
“Logic”, as used herein, includes but is not limited to hardware, fhinware, software and/or combinations of each to perform a function(s) or an action(s). For example, based on a desired application or needs, logic may include a software controlled microprocessor, discrete logic such as an application specific integrated circuit (ASIC), or other programmed logic device. Logic may also be fully embodied as software.
An “operable connection” is one in which signals and/or actual communication flow and/Or logical communication flow may be sent and/or received. Usually, an operable connection includes a physical interface, an electrical interface, and/or a data interface, but it is to be noted that an operable connection may consist of differing combinations of these or other types of connections sufficient to allow operable control.
“Signal”, as used herein, includes but is not limited to one or more electrical or optical signals, analog or digital, one or more computer instructions, a bit or bit stream, or the like.
“Software”, as used herein, includes but is not limited to, one or more computer readable and/or executable instructions that cause a computer or other electronic device to perform functions, actions and/or behave in a desired manner. The instructions may be embodied in various forms like routines, algorithms, modules, methods, threads, and/or programs. Software may also be implemented in a variety of executable and/or loadable forms including, but not limited to, a stand-alone program, a function call (local and/or remote), a servelet, an applet, instructions stored in a memory, part of an operating system or browser, and the like. It is to be appreciated that the computer readable and/or executable instructions can be located in one computer component and/or distributed between two or more communicating, co-operating, and/or parallel processing computer components and thus can be loaded and/or executed in serial, parallel, massively parallel and other manners. It will be appreciated by one of ordinary skill in the art that the foini of software may be dependent on, for example, requirements of a desired application, the environment in which it runs, and/or the desires of a designer/programmer or the like.
“Data store”, as used herein, refers to a physical and/or logical entity that can store data. A data store may be, for example, a database, a table, a file, a list, a queue, a heap, and so on. A data store may reside in one logical and/or physical entity and/or may be distributed between two or more logical and/or physical entities.
To the extent that the term “includes” is employed in the detailed description or the claims, it is intended to be inclusive in a manner similar to the term “comprising” as that term is interpreted when employed as a transitional word in a claim.
To the extent that the term “or” is employed in the claims (e.g., A or B) it is intended to mean “A or B or both”. When the author intends to indicate “only A or B but not both”, then the author will employ the term “A or B but not both”. Thus, use of the term “or” in the claims is the inclusive, and not the exclusive, use. See B RYAN A. G ARNER , A D ICTIONARY OF M ODERN L EGAL U SAGE 624 (2d Ed. 1995).
DETAILED DESCRIPTION
Example methods, systems, computer media, and so on are now described with reference to the drawings, where like reference numerals are used to refer to like elements throughout. In the following description for purposes of explanation, numerous specific details are set forth in order to facilitate thoroughly understanding the methods, systems, computer readable media, and so on. It may be evident, however, that the methods, systems and so on can be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to simplify description.
Scaling:
Controllers typically are not scalable and thus are not portable between applications. However, controllers can be made portable via scaling as described in the example systems and methods provided herein. In general, a plant mathematically represented by a transfer function G p (s), (where s is the Laplace Transform variable) can be scaled according to:
G p ( s )= kG p ( s/ω p ) (16)
where ω p is the plant frequency scale and k is the gain scale, to represent a large number of plants that differ from the original plant by a frequency scale, ω p , and a gain scale, k.
Then, a corresponding controller G c (s) for the plant G p (s) can be scaled according to:
G c ( s )=(1 /k ) G c ( s/ω p ). (17).
Consider a unit feedback control system 200 with the plant G p (s) 210 and controller G c (s) 220 , as shown in FIG. 2 . Assume that G c (s) 220 was designed with desired command following, disturbance rejection, noise rejection, and stability robustness. Now, consider a similar class of plants kG p (s/ω p ). For given ω p , using example systems and methods described herein, a suitable controller can be produced through frequency scaling. Thus define ω p as the frequency scale and k as the gain scale of the plant G p (s/ω p ) with respect to
G p ( s ). (18)
Then
G c ( s )=(1 /k ) G c ( s/ω p ). (19)
Referring to FIG. 3 , an example system 300 that employs frequency scaling is illustrated. The system 300 includes a controller identifier 310 that can identify a known controller associated with controlling a known plant. The controller may have one or more scaleable parameters (e.g., frequency, gains) that facilitate scaling the controller. The controller identifier 310 may access a controller information data store 330 and/or a plant information data store 340 to facilitate characterizing one or more properties of the known controller. By way of illustration, the controller identifier 310 may identify the frequency scale of the controller (ω c ) and/or the frequency scale (ω p ) and transfer function (s) of a plant controlled by the known controller.
The controller information data store 330 may store, for example, controller class information and/or information concerning scaleable controller parameters. Similarly, the plant data store 34 Q may store, for example, plant information like transfer function shape, frequency scale, and so on.
The system 300 may also include a controller scaler 320 that produces a scaled controller from the identified scaleable parameter. The scaler 320 may make scaling decisions based, for example, on information in the controller information data store 330 (e.g., controller class, scaleable parameters, frequency scale), information in the plant information data store 340 (e.g. plant class, plant transfer function, frequency scale), and so on.
While illustrated as two separate entities, it is to be appreciated that the identifier 310 and scaler 320 could be implemented in a single computer component and/or as two or more distributed, communicating, co-operating computer components. Thus, the entities illustrated in FIG. 3 may communicate through computer communications using signals, carrier waves, data packets, and so on. Similarly, while illustrated as two separate data stores, the controller information data store 330 and the plant information data store 340 may be implemented as a single data store and/or distributed between two or more communicating, co-operating data stores.
Aspects of controller scaling can be related to filter design. In filter design, with the bandwidth, the pass band, and stop band requirements given, filter design is straight forward. An example filter design method includes finding a unit bandwidth filter, such as an nth order Chebeshev filter H(s), that meets the pass band and stop band specifications and then frequency scaling the filter as H(s/ω 0 ) to achieve a bandwidth of ω 0 .
Revisiting the system 200 in FIG. 2 , to facilitate understanding frequency scaling and time scaling as related to controllers, denote ω p as the frequency scale of the plant G p (s/ω p ) with respect to G p (s) 210 , and τ p =1/ω p , the corresponding time scale. Then denote k as the gain scale of the plant kG p (s) with respect to G p (s) 210 . With these definitions in hand, differences in example industrial control problems can be described in terms of the frequency and gain scales. For example, temperature processes with different time constants (in first order transfer functions), motion control problems with different inertias, motor sizes, frictions, and the like can be described in terms of the defined frequency and gain scales.
These scales facilitate paying less attention to differences between controllers and applications and more attention to a generic solution for a class of problems because using the scales facilitates reducing linear time invariant plants, proper and without a finite zero, to one of the following example forms:
1 s + 1 , 1 s , 1 s 2 + 2 ξ s + 1 , 1 s ( s + 1 ) , 1 s 2 , 1 s 3 + ξ 1 s 2 + ξ 2 s + 1 , … ( 22 )
through gain and frequency scaling. For example, the motion control plant of G p (s)=23.2/s(s+1.41) is a variation of a generic motion control plant G p (s)=1/s(s+1) with a gain factor of k=11.67 and ω p =1.41.
23.2
s
(
s
+
1.41
)
=
11.67
s
1.41
(
s
1.41
+
1
)
(
23
)
Equation (22) describes many example industrial control problems that can be approximated by a first order or a second order transfer function response. Additionally, equation (22) can be appended by terms like:
s + 1 s 2 + 2 ξ s + 1 , s 2 + 2 ξ z s + 1 s 3 + ξ 1 s 2 + ξ 2 s + 1 , … ( 24 )
to include systems with finite zeros. Thus, while a set of examples is provided in equations (22) and (24), it is to be appreciated that a greater and/or lesser number of forms can be employed in accordance with the systems and methods described herein. Furthermore, in some examples, scaling can be applied to reflect the unique characteristics of certain problems. For example, a motion control system with significant resonant problems can be modeled and scaled as
k s ω p ( s ω p + 1 ) ( s ω rz ) 2 + 2 ξ z s ω rz + 1 ( s ω rp ) 2 + 2 ξ p s ω rp + 1
scaling ⇓
1 s ( s + 1 ) ( s m ) 2 + 2 ξ z s m + 1 ( s n ) 2 + 2 ξ p s n + 1 ( 25 )
where the resonant frequencies satisfy ω p =nω p , ω rz =mω p . Problems with multiple frequency scales, ω p , nω p , and mω p , can be referred to as multi-scale problems. With these definitions in hand, an example controller scaling technique is now described.
Assume G c (s) is a stabilizing controller for plant G p (s), and the loop gain crossover frequency is ω c , then the controller
G c ( s )= G c ( s/ω p )/ k (26)
will stabilize the plant G p (s)=kG p1 (s/ω p ). The new controller new loop gain
L ( s )= G p ( s ) G c ( s ) (27)
will have a bandwidth of ω c ω p , and substantially the same stability margins of
L ( s )= G p ( s ) G c ( s )
since
L ( s )= L ( s/ω p ).
Note that the new closed-loop system has substantially the same frequency response shape as the original system except that it is shifted by ω p . Thus, feedback control properties like bandwidth, disturbance and noise rejection are retained, as is the stability robustness, from the previous design, except that frequency ranges are shifted by ω p .
Now that controller scaling has been described, PID scaling can be addressed.
According to the frequency scale principle discussed above, and assuming the original controller for G p (s) is a PID, e.g.,
G c ( s ) = k p + k i s + k d s ( 28 )
then the new controller for the plant kG p (s/ω p ) is obtained from (28) as
G c ( s ) = ( k p + k i ω p s + k d s ω p ) / k ( 29 )
That is, the new PID gains, k p , k l , and k d are obtained from the original ones as
k
_
p
=
k
p
k
,
k
_
i
=
k
i
ω
p
k
,
k
_
d
=
k
d
k
ω
p
(
30
)
To demonstrate the practical application and tangible results possible from the method described above, in the following example, consider a plant that has a transfer function of
G p ( s ) = 1 s 2 + s + 1
and the PID control gains of k p =3, k i =1, and k d =2. Now, assume the plant has changed to
G p ( s ) = 1 ( s 10 ) 2 + s 10 + 1
The new gains are calculated from equation (30) as k p =3, k i =10, k d =0.2. Thus, rather than having to build, design, and tune the controller for the plant
G p ( s ) = 1 ( s 10 ) 2 + s 10 + 1
from scratch, the HD designer was able to select an existing PID appropriate for the PLD class and scale the PID. Thus, frequency scaling facilitates new systems and methods for controller design that take advantage of previously designed controllers and the relationships between controllers in related applications.
In one example, the controller is a PID controller. The PID controller may have a plant frequency scale ω p as a scaleable parameter. In another example, the method includes producing the scaled controller. For example, a computer component may be programmed to perform the frequency scaled controlling. Additionally, computer executable portions of the method may be stored on a computer readable medium and/or be transmitted between computer components by, for example, carrier waves encoding computer executable instructions.
In view of the exemplary systems shown and described below, example methodologies that are implemented will be better appreciated with reference to the flow diagrams of FIGS. 4 , 5 and 13 . While for purposes of simplicity of explanation, the illustrated methodologies are shown and described as a series of blocks, it is to be appreciated that the methodologies are not limited by the order of the blocks, as some blocks can occur in different orders and/or concurrently with other blocks from that shown and described. Moreover, less than all the illustrated blocks may be required to implement an example methodology. Furthermore, additional and/or alternative methodologies can employ additional, not illustrated blocks. In one example, methodologies are implemented as computer executable instructions and/or operations, stored on computer readable media including, but not limited to an application specific integrated circuit (ASIC), a compact disc (CD), a digital versatile disk (DVD), a random access memory (RAM), a read only memory (ROM), a programmable read only memory (PROM), an electronically erasable programmable read only memory (EEPROM), a disk, a carrier wave, and a memory stick.
In the flow diagrams, rectangular blocks denote “processing blocks” that may be implemented, for example, in software. Similarly, the diamond shaped blocks denote “decision blocks” or “flow control blocks” that may also be implemented, for example, in software. Alternatively, and/or additionally, the processing and decision blocks can be implemented in functionally equivalent circuits like a digital signal processor (DSP), an ASIC, and the like.
A flow diagram does not depict syntax for any particular programming language, methodology, or style (e.g., procedural, object-oriented). Rather, a flow diagram illustrates functional information one skilled in the art may employ to program software, design circuits, and so on. It is to be appreciated that in some examples, program elements like temporary variables, initialization of loops and variables, routine loops, and so on are not shown.
Turning to FIG. 5 , a flowchart for an example method 500 for producing a controller is illustrated. The method 500 includes, at 510 , identifying a controller G c (s) that stabilizes a plant G p (s) where the controller has a frequency ω c and, at 520 , producing a controller G c (s) by scaling the controller G c (s) according to k c (s)=G c (s/ω p )/k, where the controller G c (s) will stabilize the plant G p (s)=kG p1 (s/ω p ), where ω p is the frequency scale of the plant G p (s/ω p ), and where k is the gain scale of the plant kG p (s). In one example, the controller is a PID controller of the form
G c ( s ) = k p + k i s + k d s ,
where k p is a proportional gain, k i is an integral gain, and k d is a derivative gain. In another example,
G c ( s ) = ( k p + k i ω p s + k d s ω p ) / k .
In yet another example, the PID gains k p , k i , and k d are obtained from the k p , k i , and k d according to
k _ p = k p k , k _ i = k i ω p k , k _ d = k d k ω p .
It is to be appreciated that this example method can be employed with linear and/or non-linear PIDs.
Applying a unit step function as the set point, the responses of an original controller and a scaled controller are shown in FIG. 6 , demonstrating that the response of the scaled controller is substantially the same as the response of the original controller, but scaled by τ=1/ω 0 . The gain margins of both systems are substantially infinite and the phase margins are both approximately 82.372 degrees. The 0 dB crossover frequency for both systems are 2.3935 and 23.935 r/s, respectively. Thus, the PID scaled by the example method is demonstrably appropriate for the application.
While the method described above concerned linear PIDs, it is to be appreciated that the method can also be applied to scaling nonlinear PIDs. For example, PID performance can be improved by using nonlinear gains in place of the linear ones. For example,
u=k p g p ( e )+ k i ∫g i ( e ) dt+k d g d ( e ) (31)
where g p (e), g i (e), and g d (e) are nonlinear functions. The non-linear PLDs can be denoted NPID. Nonlinearities are selected so that the proportional control is more sensitive to small errors, the integral control is limited to the small error region—which leads to significant reduction in the associate phase lag—and the differential control is limited to a large error region, which reduces its sensitivity to the poor signal to noise ratio when the response reaches steady state and the error is small.
The NPID retains the simplicity of PID and the intuitive tuning. The same gain scaling formula (30) will also apply to the NPID controller when the plant changes from G p (s) to kG p (s/ω p ).
Scaling facilitates concentrating on normalized control problems like those defined in (22). This facilitates selecting an appropriate controller for an individual problem by using the scaling formula in (26) and the related systems and methods that produce tangible, results (e.g., scaled controller). This further facilitates focusing on the fundamentals of control, like basic assumptions, requirements, and limitations. Thus, the example systems, methods, and so on described herein concerning scaling and parameterization can be employed to facilitate optimizing individual solutions given the physical constraints of a problem.
Parameterization
Working with controllers can be simplified if they can be described in terms of a smaller set of parameters than is conventionally possible. Typically, a controller (and possibly an observer) may have many (e.g. 15) parameters. The systems and methods described herein concerning parameterization facilitate describing a controller in terms of a single parameter. In one example, controller parameterization concerns making controller parameters functions of a single variable, the controller bandwidth ω n .
Considering the normalized plants in (22) and assuming desired closed-loop transfer functions are:
ω c s + ω c , ω c 2 ( s + ω c ) 2 , ω c 3 ( s + ω c ) 3 , … ( 32 )
then for second order plants, the damping ratio can be set to unity, resulting in two repeatea poles at −ω c . The same technique can also be applied to higher order plants.
Applying pole-placement design to the first and second order plants in (22), a set of example ω c parameterized controllers are obtained and shown in Table I. Information concerning the plants and the related controllers can be stored, for example, in a data store.
TABLE I
Examples of ω c -parameterized controllers
G p (s)
1
s
+
1
1
s
1
s
2
+
2
ξs
+
1
1
s
(
s
+
1
)
1
s
2
G c (s, ω c )
ω
c
(
s
+
1
)
s
ω c
ω
c
2
s
2
+
2
ξs
+
1
s
(
s
+
2
ω
c
)
ω
c
2
(
s
+
1
)
s
+
2
ω
c
ω
c
2
s
s
+
2
ω
c
Loop shaping design can also be parameterized. Loop-shaping refers to manipulating the loop gain frequency response, L(jω)=G p (jω)G c (jω), as a control design tool. One example loop-shaping method includes converting design specifications to loop gain constraints, as shown in FIG. 7 and finding a controller G c (jω) to meet the specifications.
As an example of loop shaping, considering the plants of the form G p (s), in Table I, the desired loop gain can be characterized as
L ( s ) = G p ( s ) G c ( s ) = ( s + ω 1 s ) m 1 s ω c + 1 1 ( s ω 2 + 1 ) n ( 33 )
where ω c is the bandwidth, and
ω 1 <ω c ,ω 2 >ω c ,m≧ 0, and n≧ 0 (34)
are selected to meet constrains shown in FIG. 7 . In the example, both m and n are integers. In one example, default values for ω 1 and ω 2 are
ω 1 =ω c /10 and ω 2 =10ω c (35)
which yield a phase margin greater than forty-five degrees.
Once appropriate loop gain constraints are derived and the corresponding lowest order L(s) in (33) is selected, the controller can be determined from
G c ( s ) = ( s + ω 1 s ) m 1 s ω c + 1 1 ( s ω 2 + 1 ) n G p - 1 ( s ) ( 36 )
An additional constraint on n is that
1 s ω c + 1 1 ( s ω 2 + 1 ) n G p - 1 ( s ) is proper . ( 37 )
This design is valid for plants with a minimum phase. For a non-minimum phase plant, a minimum phase approximation of G p −1 (s) can be employed.
A compromise between ω 1 and the phase margin can be made by adjusting ω 1 upwards, which will improve the low frequency properties at the cost of reducing phase margin. A similar compromise can be made between phase margin and ω 2 .
Turning to FIG. 4 , an example method 400 for scaling a controller is illustrated. The method 400 includes, at 410 , identifying a known controller in a controller class where the known controller controls a first plant. The method 400 also includes, at 420 , identifying a scaleable parameter for the known controller. At 430 , the method 400 includes identifying a desired controller in the controller class, where the desired controller controls a second, frequency related plant and at 440 , establishing the frequency relation between the known controller and the desired controller. At 450 , the method 400 scales the known controller to the desired controller by scaling the scaleable parameter based, at least in part, on the relation between the known controller and the desired controller.
Practical Optimization Based on a Hybrid Scaling and Parameterization Method
Practical controller optimization concerns obtaining optimal performance out of existing hardware and software given physical constraints. Practical controller optimization is measured by performance measurements including, but not limited to, command following quickness (a.k.a. settling time), accuracy (transient and steady state errors), and disturbance rejection ability (e.g., attenuation magnitude and frequency range). Example physical constraints include, but are not limited to, sampling and loop update rate, sensor noise, plant dynamic uncertainties, saturation limit, and actuation signal smoothness requirements.
Conventional tuning relies, for example, on minimizing a cost function like H 2 and However, conventional cost functions may not comprehensively reflect the realities of control engineering, and may, therefore, lead to suboptimal tuning. For example, one common cost function is mathematically attractive but can lead to suboptimal controller tuning. Thus, optimizing other criteria, like ω c are considered.
A typical industrial control application involves a stable single-input single-output (SISO) plant, where the output represents a measurable process variable to be regulated and the input represents the control actuation that has a certain dynamic relationship to the output. This relationship is usually nonlinear and unknown, although a linear approximation can be obtained at an operating point via the plant response to a particular input excitation, like a step change.
Evaluating performance measurements in light of physical limitations yields the fact that they benefit from maximum controller bandwidth ω c . If poles are placed in the same location, then ω c can become the single item to tune. Thus, practical PID optimization can be achieved with single parameter tuning. For example, in manufacturing, a design objective for an assembly line may be to make it run as fast as possible while minimizing the down time for maintenance and trouble shooting. Similarly, in servo design for a computer hard disk drive, a design objective may be to make the read/write head position follow the setpoint as fast as possible while maintaining extremely high accuracy. In automobile anti-lock brake control design, a design objective may be to have the wheel speed follow a desired speed as closely as possible to achieve minimum braking distance.
In the three examples, the design goal can be translated to maximizing controller bandwidth ω c . There are other industrial control examples that lead to the same conclusion. Thus, ω c maximization appears to be a useful criterion for practical optimality. Furthermore, unlike purely mathematical optimization techniques, ω c optimization has real world applicability because it is limited by physical constraints. For example, sending ω c to infinity may be impractical because it may cause a resulting signal to vary unacceptably.
As an example of how physical limitations may affect ω c optimization, consider digital control apparatus that have a maximum sampling rate and a maximum loop update rate. The maximum sampling rate is a hardware limit associated with the Analog to Digital Converter (ADC) and the maximum loop update rate is software limit related to central processing unit (CPU) speed and the control algorithm complexity. Typically, computation speeds outpace sampling rates and therefore only the sampling rate limitation is considered.
As another example, measurement noise may also be considered when examining the physical limitations of ω c optimization. For example, the ω c is limited to the frequency range where the accurate measurement of the process variable can be obtained. Outside of this range, the noise can be filtered using either analog or digital filters.
Plant dynamic uncertainty may also be considered when examining the physical limitations of ω c optimization. Conventional control design is based on a mathematical description of the plant, which may only be reliable in a low frequency range. Some physical plants exhibit erratic phase distortions and nonlinear behaviors at a relative high frequency range. The controller bandwidth is therefore limited to the low frequency range where the plant is well behaved and predictable. To safeguard the system from instability, the loop gain is reduced where the plant is uncertain. Thus, maximizing the bandwidth safely amounts to expanding the effective (high gain) control to the edge of frequency range where the behavior of the plant is well known.
Similarly, actuator saturation and smoothness may also affect design. Although using transient profile helps to decouple bandwidth design and the transient requirement, limitations in the actuator like saturation, nonlinearities like backlash and hysteresis, limits on rate of change, smoothness requirements based on wear and tear considerations, and so on may affect the design. For example, in a motion control application with a significant backlash problem in the gearbox, excessively high bandwidth will result in a chattering gearbox and, very likely, premature breakdown. Thus, ω c optimization, because it considers physical limitations like sampling rate, loop update rate, plant uncertainty, actuator saturation, and so on, may produce improved performance.
In one controller optimization example, assume that the plant is minimum phase, (e.g., its poles and zeros are in the left half plane), that the plant transfer function is given, that the ω c parameterized controllers are known and available in form of Table I, that a transient profile is defined according to the transient response specifications, and that a simulator 800 of closed-loop control system as shown in FIG. 8 is available. It is to be appreciated that the closed loop control system simulator 800 can be, for example, hardware, software or a combination of both. In one example, the simulator incorporates limiting factors including, but not limited to, sensor and quantization noises, sampling disturbances, actuator limits, and the like.
With these assumptions, one example design method then includes, determining frequency and gain scales, w, and k from the given plant transfer function. The method also includes, based on the design specification, determining the type of controller required from, for example, Table I. The method also includes selecting the G c (s, ω c ) corresponding to the scaled plant in the form of Table I. The method also includes scaling the controller to
1 k G c ( s ω p , ω c ) ,
digitizing G c (s/ω p , ω c )/k and implementing the controller in the simulator. The method may also include setting an initial value of ω c based on the bandwidth requirement from the transient response and increasing ω c while performing tests on the simulator, until either one of the following is observed:
a. Control signal becomes too noisy and/or too uneven, or b. Indication of instability (oscillatory behavior)
Consider an example motion control test bed for which the mathematical model of the motion system is
ÿ =(−1.41 {dot over (y)}/+ 23.27 T d )+23.2 u (38)
where y is the output position, u is the control voltage sent to the power amplifier that drives the motor, and T d is the torque disturbance. An example design objective for the example system could be rotating the load one revolution in one second with no overshoot. Thus, the physical characteristics of the example control problem are:
1) |u|<3.5 volt,
2) sampling rate=1 kHz,
3) sensor noise is 0.1% white noise,
4) torque disturbance up to 10% of the maximum torque,
5) smooth control signal.
The plant transfer function is
G p ( s ) = k s ω p ( s ω p + 1 ) , k = 11.67 and ω p = 1.41 .
Now consider the corresponding UGUB plant
G _ p ( s ) = 1 s ( s + 1 ) .
A PD design of
u=k p ( r−y )+ k d (−{dot over ( y )})
with
k p =ω c 2 and k d =2ω c −1
makes the closed-loop transfer function
G cl ( s ) = ω c 2 ( s + ω c ) 2 .
Considering the plant gain scale of k and the frequency scale of ω p , the PD gains are then scaled as
k p = ω c 2 k = .086 ω c 2 and k d = 2 ω c - 1 k ω p = .061 ( 2 ω c - 1 ) .
To avoid noise corruptions of the control signal, an approximate differentiator
s ( s 10 ω c + 1 ) 2
is used where the corner frequency 10ω c is selected so that the differentiator approximation does not introduce problematic phase delays at the crossover frequency. Using a conventional root locus method, the one second settling time would require a closed-loop bandwidth of 4 rad/sec. The example single parameter design and tuning methods described herein facilitate determining that an ω c of 20 rad/sec yields optimal performance under the given conditions. A comparison of the two designs is shown in FIG. 9 . Note that a step disturbance of 1 volt is added at t=3 seconds to test disturbance rejection. Finally, a trapezoidal transient profile is used in place of the step command. The results are shown in FIG. 10 .
Parameterization of State Feedback and State Observer Gains
As described in the Background section, the State Feedback (SF) controller
u=r+K{circumflex over (x)} (4)
is based on the state space model of the plant:
{circumflex over (x)} ( t )= Ax ( t )+ Bu ( t ), y ( t )= Cx ( t )+ Du ( t ) (5)
When the state x is not accessible, a state observer (SO):
{circumflex over (x)} =A{circumflex over (x)}+Bu+L ( y−ŷ ) (6)
is often used to find its estimate, {circumflex over (x)}. Here r is the setpoint for the output to follow. The state feedback gain K and the observer gain L are determined from the equations:
eig( A+BK )=λ c ( s ) and eig( A+LC )=λ o ( s )
where λ c (s) and λ o (s) are polynomials of s that are chosen by the designer. Usually the K and L have many parameters and are hard to tune.
The parameterization of state feedback and state observer gains are achieved by making
λ c ( s )=( s+ω c ) n and λ o ( s )=( s+ω o ) n
where ω c and ω o are bandwidth of the state feedback system and the state observer, respectively, and n is the order of the system. This simplifies tuning since parameters in K and L are now functions of ω c and ω o , respectively.
Parameterization of Linear Active Disturbance Rejection Controller (LADRC) for a Second Order Plant
Some controllers are associated with observers. Conventionally, second order systems with controllers and observers may have a large number (e.g., 15) tunable features in each of the controller and observer. Thus, while a design method like the Hann method is conceptually viable, its practical implementation is difficult because of tuning issues. As a consequence of the scaling and parameterization described herein, observer based systems can be constructed and tuned using two parameters, observer bandwidth (ω 0 ) and controller bandwidth (ω c ).
State observers provide information on the internal states of plants. State observers also function as noise filters. A state observer design principle concerns how fast the observer should track the states, (e.g., what should its bandwidth be). The closed-loop observer, or the correction term L(y−ŷ) in particular, accommodates unknown initial states, uncertainties in parameters, and disturbances. Whether an observer can meet the control requirements is largely dependent on how fast the observer can track the states and, in case of ESO, the disturbance ƒ(t,x i ,x 2 ,w). Generally speaking, faster observers are preferred. Common limiting factors in observer design include, but are not limited to dependency on the state space model of the plant, sensor noise, and fixed sampling rate.
Dependency on the state space model can limit an application to situations where a model is available. It also makes the observer sensitive to the inaccuracies of the model and the plant dynamic changes. The sensor noise level is hardware dependent, but it is reasonable to assume it is a white noise with the peak value 0.1% to 1% of the output. The observer bandwidth can be selected so that there is no significant oscillation in its states due to noises. A state observer is a closed-loop system by itself and the sampling rate has similar effects on the state observer performance as it does on feedback control. Thus, an example model independent state observer system is described.
Observers are typically based on mathematical models. Example systems and methods described herein can employ a “model independent” observer as illustrated in FIG. 18 . For example a plant 1820 may have a controller 1810 and an observer 1830 . The controller 1810 may be implemented as a computer component and thus may be programmatically tunable. Similarly, the observer 1830 may be implemented as a computer, component and thus may have scaleable parameters that can be scaled programmatically. Furthermore, using analogous scaling and parameterizing as described herein, the parameters of the observer 1830 can be reduced to ω o . Therefore, overall optimizing of the system 1800 reduces to tuning ω c and ω o .
Consider a simple example for controlling a second order plant
ÿ=−a{dot over (y)}−by+w+bu (39)
where y and u are output and input, respectively, and w is an input disturbance. Here both parameters, a and b, are unknown, although there is some knowledge of b, (e.g., b 0 ≈b, derived from the initial acceleration of y in step response). Rewrite (39) as
ÿ=−a{dot over (y)}−by+w +( b−b 0 ) u+b 0 u=ƒ+b 0 u (40)
where ƒ=−a{dot over (y)}−by+w+(b−b 0 )u. Here ƒ is referred to as the generalized disturbance, or disturbance, because it represents both the unknown internal dynamics, −a{dot over (y)}−by+(b−b 0 )u and the external disturbance w(t).
If an estimate of ƒ; {circumflex over (ƒ)} can be obtained, then the control law
u = - f ^ + u 0 b 0
reduces the plant to ÿ=(ƒ−{circumflex over (ƒ)})+u 0 which is a unit-gain double integrator control problem with a disturbance (ƒ−{circumflex over (ƒ)}).
Thus, rewrite the plant in (40) in state space form as
{ x . 1 = x 2 x . 2 = x 3 + b 0 u x . 3 = h y = x 1 ( 41 )
with x 3 =ƒ added as an augmented state, and h={dot over (ƒ)} is seen as an unknown disturbance. Now ƒ can be estimated using a state observer based on the state space model
{dot over (x)}=Ax+Bu+Eh
y=Cz (42)
where
A = [ 0 1 0 0 0 1 0 0 0 ] , B = [ 0 b 0 0 ] , C = [ 1 0 0 ] , E = [ 0 0 1 ]
Now the state space observer, denoted as the linear extended state observer (LESO), of (42) can be constructed as
ż=Az+Bu+L ( y−ŷ ) (43)
ŷ=Cz
which can be reconstructed in software, for example, and L is the observer gain vector, which can be obtained using various methods known in the art like pole placement,
L=[β 1 β 2 β 3 ] T (44)
where [ ] T denotes transpose. With the given state observer, the control law can be given as:
u = - z 3 + u 0 b 0 ( 45 )
Ignoring the inaccuracy of the observer,
ÿ =( ƒ−z 3 )+ u 0 ≈u 0 (46)
which is an unit gain double integrator that can be implemented with a PD controller
u 0 =k p ( r−z 1 )− k a z 2 (47)
where r is the setpoint. This results in a pure second order closed-loop transfer function of
G cl = 1 s 2 + k d s + k p ( 48 )
Thus, the gains can be selected as
k d =2ξω c and k p =ω c 2 (49)
where ω c and ζ are the desired closed loop natural frequency and damping ratio. ζ can be chosen to avoid oscillations. Note that −k d z 2 , instead of k d ({dot over (r)}−z 2 ), is used to avoid differentiating the setpoint and to make the closed-loop transfer function a pure second order one without a zero.
This example illustrates that disturbance observer based PD control achieves zero steady state error without using the integral part of a PID controller. The example also illustrates that the design is model independent in that the design relies on the approximate value of b in (39). The example also illustrates that the combined effects of the unknown disturbance and the internal dynamics are treated as a generalized disturbance. By augmenting the observer to include an extra state, it is actively estimated and canceled out, thereby achieving active disturbance rejection. This LESO based control scheme is referred to as linear active disturbance rejection control (LADRC) because the disturbance, both internal and external, represented by ƒ, is actively estimated and eliminated.
The stability of controllers can also be examined. Let e i =x i −z i , i=1, 2, 3. Combine equation (43) and (44) and subtract the combination from (42). Thus, the error equation can be written:
ė=A e e+Eh (50)
where
A e = A - LC = [ - β 1 1 0 - β 2 0 1 - β 3 0 0 ]
and E is defined in (42). The LESO is bounded input, bounded output (BIBO) stable if the roots of the characteristic polynomial of A e
λ( s )= s 3 +β 1 s 2 β 2 s+β 3 (51)
are in the left half plane (LHP) and h is bounded. This separation principle also applies to LADRC.
The LADRC design from (43) to (46) yields a BIBO stable closed-loop system if the observer in (43) and (44) and the feedback control law (46) for the double integrator are stable, respectively. This is shown by combing equations (45) and (47) into a state feedback form of u=(1/b 0 )[−k p −k d −1]z=Fz, where F=(1/b 0 )[−k p −k d −1]. Thus, the closed-loop system can be represented by the state-space equation of
[ x . z . ] = [ A B _ F LC A - LC + B _ F ] [ x z ] + [ [ B _ E ] [ B _ 0 ] ] [ r h ] ( 52 )
where B =B/b 0 , and which is BIBO stable if its eigenvalues are in the LHP. By applying row and column operations, the closed-loop eigenvalues
eig
(
[
A
B
_
F
LC
A
-
LC
+
B
_
F
]
)
=
eig
(
[
A
+
B
_
F
B
_
F
0
A
-
LC
]
)
=
eig
(
A
=
BF
)
⋃
eig
(
A
-
LC
)
=
{
roots
of
s
2
+
k
d
s
+
k
p
}
⋃
{
roots
of
s
3
+
β
1
s
2
+
β
2
s
2
+
β
3
}
Since r is the bounded reference signal, a nontrivial condition on the plant is that h={dot over (ƒ)} is bounded. In other words, the disturbance ƒ must be differentiable.
Observer Bandwidth Parameterization
ω o parameterization refers to parameterizing the ESO on observer bandwidth ω o . Consider a plant (42) that has three poles at the origin. The related observer will be less sensitive to noises if the observer gains in (44) are small for a given ω o . But observer gains are proportional to the distance for the plant poles to those of the observer. Thus the three observer poles should be placed at −ω o , or equivalently,
λ( s )= s 3 +β 1 s 2 +β 2 s+β 3 =( s+ω o ) 3 (53)
That is
β 1 =3ω o ,β 2 =3ω o 2 ,β 3 =ω o 3 (54)
It is to be appreciated by one of ordinary skill in the art that equations (53) and (54) are extendable to nth order ESO. Similarly, the parameterization method can be extended to the Luenberger Observer for arbitrary A, B, and C matrices, by obtaining {Ā, B , C } as observable canonical form of {A,B,C}, determining the observer gain, L , so that the poles of the observer are at −ω o and using the inverse state transformation to obtain the observer gain, L, for {A,B,C}. The parameters in L are functions of ω o . One example procedure for ω o optimization based design is now described.
Given tolerable noise thresholds in the observer states, increase ω o until at least one of the thresholds is about to be reached or the observer states become oscillatory due to sampling delay. In general, the faster the ESO, the faster the disturbance is observed and cancelled by the control law.
A relationship between ω o and ω c can be examined. One example relationship is
ω o ≈3␣5ω c (55)
Equation (55) applies to a state feedback control system where ω o is determined based on transient response requirements like the settling time specification. Using a transient profile instead of a step command facilitates more aggressive control design. In this example there are two bandwidths to consider, the actual control loop bandwidth ω c and the equivalent bandwidth of the transient profile, ω c . Part of the design procedure concerns selecting which of the two to use in (55). Since the observer is evaluated on how closely it tracks the states and ω c is more indicative than ω c on how fast the plant states move, ω c is the better choice, although it is to be appreciated that either can be employed. Furthermore, taking other design issues like the sampling delay into consideration, a more appropriate minimum ω o is found through simulation and experimentation as
ω o ≈5␣10ω c (56)
An example for optimizing LADRC is now presented. One example LADRC design and optimization method includes designing a parameterized LESO and feedback control law where ω o and ω c are the design parameters. The method also includes designing a transient profile with the equivalent bandwidth of ω c and selecting an ω o from (56). The method then includes setting ω c =ω o and simulating and/or testing the LADRC in a simulator. The method also includes incrementally increasing ω c and ω o by the same amount until the noise levels and/or oscillations in the control signal and output exceed the tolerance. The method also includes incrementally increasing or decreasing ω c and ω c individually, if necessary, to make trade-offs between different design considerations like the maximum error during the transient period, the disturbance attenuation, and the magnitude and smoothness of the controller.
In one example, the simulation and/or testing may not yield satisfactory results if the transient design specification described by ω c is untenable due to noise and/or sampling limitations. In this case, control goals can be lowered by reducing ω c and therefore ω c and ω o . It will be appreciated by one skilled in the art that this approach can be extended to Luenbergtate observer based state feedback design.
By way of illustration, reconsider the control problem example associated with equations (32), but apply the LADRC in (43) to (48). Note that b=23.2 for this problem, but to make the design realistic, assume the designer's estimate of b is b 0 =40. Now rewrite the plant differential equation (38) as
ÿ (−1.41 ÿ+ 23.2 T )+(23.2−40) u+ 40 u=ƒ+ 40 u
The LESO is
z . = [ - 3 ω o 1 0 - 3 ω o 2 0 1 - ω o 3 0 0 ] z + [ 0 3 ω o 40 3 ω o 2 0 ω o 3 ] [ u y ]
and
z 1 →y,z 2 →{dot over (y)}, and
z 1 →ƒ=−1.41 {dot over (y)}+ 23.2 T d +(23.2−40) u , as t→∞
The control law is defined as
u = u 0 - z 3 40 and u 0 = k p ( r - z 1 ) - k d z 2
with
k d =2ξω c ,ξ=1, and k p =ω c 2
where ω c is the sole design parameter to be tuned. A trapezoidal transient profile is used with a settling time of one second, or ω c =4. From (56), ω o is selected to be 40 rad/sec. The LADRC facilitates design where a detailed mathematical model is not required, where zero steady state error is achieved without using the integrator term in PID, where there is better command following during the transient stage and where the controller is robust. This performance is achieved by using a disturbance observer. Example performance is illustrated in FIG. 12 .
Parameterization of LADRC for Nth Order Plant
It will be appreciated by one skilled in the art that observer based design and tuning techniques can be scaled to plants of arbitrary orders. For a general nth order plant with unknown dynamics and external disturbances,
y (n) =ƒ( t,y,{dot over (y)}, . . . ,y (n−1) ,u,{dot over (u)}, . . . u (n−1) ,w )+ bu (57)
the observer can be similarly derived, starting from the state space equation
{ x . 1 = x 2 x . 2 = x 3 … x . n = x n + 1 + b 0 u x . n + 1 = h y = x 1 ( 58 )
with x n+1 =ƒ added as an augmented state, and h={dot over (ƒ)} mostly unknown. The observer of (43) in its linear form with the observer gain
L=[β 1 ,β 2 . . . β n+1] (59)
has the form
{
z
.
1
=
x
2
-
β
1
(
z
1
-
y
(
t
)
)
z
.
2
=
z
3
-
β
2
(
z
1
-
y
(
t
)
)
…
z
.
n
=
z
n
+
1
-
β
n
(
z
1
-
y
(
t
)
)
+
b
0
u
z
.
n
+
1
=
-
β
n
+
1
(
z
1
-
y
(
t
)
)
(
60
)
With the gains properly selected, the observer will track the states and yield
z 1 ( t )→ y ( t ), z 2 ( t )→{dot over ( y )}( t ), . . . , z n ( t )→ y (n−1) ( t )
z n+1 ( t )→ƒ( t,y,{dot over (y)}, . . . ,y (n−1) ,u,{dot over (u)}, . . . u (n−1) ,w ) (61)
The control law can also be similarly designed as in (45) and (47), with
u = - z n + 1 + u 0 b 0 ( 62 )
which reduces the plant to approximately a unit gain cascaded integrator plant
y (n) =( ƒ−z n+1 )+ u 0 ≈u 0 (63)
and
u 0 =k p ( r−z 1 )− k d i z 2 − . . . −k d i z n (64)
where the gains are selected so that the closed-loop characteristic polynomial has n poles at −ω c ,
s n +k d n−1 s n−1 + . . . +k d 1 s+h p =( s+ω c ) n (65)
ω c is the closed-loop bandwidth to be optimized in tuning. The ω o optimization can similarly be applied using
s n +β 1 s n−1 + . . . +β n−1 s+β n =( s+ω o ) n (66)
The following example method can be employed to identify a plant order and b 0 . Given a “black box” plant with input u and output y, the order, n, and b 0 can be estimated by allowing the plant to discharge energy stored internally so that it has a zero initial condition, (e.g., y(0)={dot over (y)}(0)= . . . y (n−1) (0)=0) and then assuming ƒ(0)=0. The method includes applying a set of input signals and determining the initial slope of the response: {dot over (y)}(0 + ), ÿ(0 + ), . . . . The method also includes determining the slope y (i) (0 + ) that is proportional to u(0) under various tests, (e.g., y (i) (0 + )=ku(0)). Then the method includes setting n=i+1 and b 0 =k.
Auto-Tuning Based on the New Scaling, Parameterization and Optimization Techniques
Auto-tuning concerns a “press button function” in digital control equipment that automatically selects control parameters. Auto-tuning is conventionally realized using an algorithm to calculate the PID parameters based on the step response characteristics like overshoot and settling time. Auto-tuning has application in, for example, the start up procedure of closed-loop control (e.g., commissioning an assembly line in a factory). Auto-tuning can benefit from scaling and parameterization.
In some applications, dynamic changes in the plant during operations are so severe that controller parameters are varied from one operating point to another. Conventionally, gain-scheduling is employed to handle these situations. In gain-scheduling, the controller gains are predetermined for different operating points and switched during operations. Additionally, and/or alternatively, self-tuning that actively adjusts control parameters based on real time data identifying dynamic plant changes is employed.
Common goals of these techniques are to make the controller parameter determination automatic, given the plant response to a certain input excitation, say a step function and to maintain a consistent controller performance over a wide range of operations, (e.g. making the controller robust).
Example systems, methods and so on described herein concerning scaling and parameterization facilitate auto-scaling model based controllers. When a transfer function model of a plant is available, the controller can be designed using either pole placement or loop shaping techniques. Thus, example scaling techniques described herein facilitate automating controller design and tuning for problems including, but not limited to, motion control, where plants are similar, differing only in dc gain and the bandwidth, and adjusting controller parameters to maintain high control performance as the bandwidth and the gain of the plant change during the operation.
In the examples, the plant transfer functions can be represented as G p (s)=kG p (s/ω p ), where G p (s) is given and known as the “mother” plant and k and ω p are obtained from the plant response or transfer function. Assuming the design criteria are similar in nature, differing only in terms of the loop gain bandwidth, ω c , the controller for similar plants can be automatically obtained by scaling the given controller, G c (s,ω c ), for G p (s). This is achieved by combining the controller scaling, defined in equation (26), and ω c -parameterization to obtain the controller for G p (s)=kG p (s/ω p ) as
G ( s,ω c )= G c ( s/ω p ,ω c )/ k (67)
There are three parameters in (67) that are subject to tuning. The first two parameters, k and ω p , represent plant changes or variations that are determined. The third parameter, ω c , is tuned to maximize performance of the control system subject to practical constraints.
An example method for auto-tuning is now described. The auto-tuning method includes examining a plant G p (s) and the nominal controller G c (s,ω c ). Given the plant G p (s) and the nominal controller G c (s,ω c ), the method includes performing off-line tests to determine k and ω p for the plant. The method also includes using equation (67) to determine a new controller for the plant, G p (s)=kG p (s/ω p ), obtained in the previous act. The method also includes optimizing ω c for the new plant.
An example method for adaptive self-tuning is now described. The adaptive self-tuning procedure includes examining a plant G (s)=kG p (s/ω p ), where k and ω p are subject to change during plant operation. Given the plant G =kG p (s/ω p ), the method includes performing real time parameter estimation to determine k and ω p as they change. The method also includes determining when the performance of the control system is degraded beyond a pre-determined, configurable threshold and updating the controller using (67). The method also includes selectively decreasing ω c if the plant dynamics deviate significantly from the model kG p (s/ω p ), which causes performance and stability problems. The method also includes selectively increasing ω c subject to ω c -optimization constraints if the plant model can be updated to reflect the changes of the plant beyond k and ω p .
The LADRC technique does not require the mathematical model of the plant. Instead, it employs a rough estimate of the single parameter b in the differential equation of the plant (57). This estimation is denoted as b 0 and is the sole plant parameter in LADRC. As the dynamics of the plant changes, so does b. Thus, b 0 can be estimated by rewriting (57) as
y (n) =ƒ( t )+ bu (69)
and assuming the zero initial condition, (e.g., y (i) (0)=0, i=1, 2, . . . n−1 and ƒ(0)=0). Then b 0 ≈b can be estimated by using
b 0 =y (n) (0 + )/ u (0) (70)
where u(0) is the initial value of the input. It is to be appreciated that this method can be applied to both open loop and closed-loop configurations. For the auto-tuning purposes, the test can be performed off-line and a step input, u(t)=constant can be applied. The LADRC does not require b 0 to be highly accurate because the difference, b−b 0 , is treated as one of the sources of the disturbance estimated by LESO and cancelled by control law.
The b 0 obtained from the off-line estimation of b described above can be adapted for auto-tuning LADRC. An auto-tuning method includes, performing off-line tests to determine the order of the plant and b 0 , selecting the order and the b 0 parameter of the LADRC using the results of the off-line tests, and performing a computerized auto-optimization.
Using the controller scaling, parameterization and optimization techniques presented herein, an example computer implemented method 1300 as shown in FIG. 13 can be employed to facilitate automatically designing and optimizing the automatic controls (ADOAC) for various applications. The applications include, but are not limited to, motion control, thermal control, pH control, aeronautics, avionics, astronautics, servo control, and so on.
The method 1300 , at 1310 , accepts inputs including, but not limited to, information concerning hardware and software limitations like the actuator saturation limit, noise tolerance, sampling rate limit, noise levels from sensors, quantization, finite word length, and the like. The method also accepts input design requirements like settling time, overshoot, accuracy, disturbance attenuation, and so on. Furthermore, the method also accepts as input the preferred control law form like, PID form, model based controller in a transfer function form, and model independent LADRC form. In one example, the method can indicate if the control law should be provided in a difference equation form. At 1320 , a determination is made concerning whether a model is available. If a model is available, then at 1330 the model is accepted either in transfer function, differential equations, or state space form. If a model is not available, then the method may accept step response data at 1340 . Information on significant dynamics that is not modeled, such as the resonant modes, can also be accepted.
Once the method has received information input, the method can check design feasibility by evaluating the specification against the limitations. For example, in order to see whether transient specifications are achievable given the limitations on the actuator, various transient profiles can be used to determine maximum values of the derivatives of the output base on which the maximum control signal can be estimated. Thus, at 1350 , a determination is made concerning whether the design is feasible. In one example, if the design is not feasible, processing can conclude. Otherwise, processing can proceed to 1360 .
If the input information passes the feasibility test, then at 1360 , the method 1300 can determine an ω c parameterized solution in one or more formats. In one example, the ω c solution can then be simulated at 1370 to facilitate optimizing the solution.
In one example, to assist an engineer or other user, the ADOAC method provides parameterized solutions of different kind, order, and/or forms, as references. The references can then be ranked separately according to simplicity, command following quality, disturbance rejection, and so on to facilitate comparison.
FIG. 14 illustrates a computer 1400 that includes a processor 1402 , a memory 1404 , a disk 1406 , input/output ports 1410 , and a network interface 1412 operably connected by a bus 1408 . Executable components of the systems described herein may be located on a computer like computer 1400 . Similarly, computer executable methods described herein may be performed on a computer like computer 1400 . It is to be appreciated that other computers may also be employed with the systems and methods described herein. The processor 1402 can be a variety of various processors including dual microprocessor and other multi-prbcessor architectures. The memory 1404 can include volatile memory and/or non-volatile memory. The non-volatile memory can include, but is not limited to, read only memory (ROM), programmable read only memory (PROM), electrically programmable read only memory (EPROM), electrically erasable programmable read only memory (EEPROM), and the like. Volatile memory can include, for example, random access memory (RAM), synchronous RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double data rate SDRAM (DDR SDRAM), and direct RAM bus RAM (DRRAM). The disk 1406 can include, but is not limited to, devices like a magnetic disk drive, a floppy disk drive, a tape drive, a Zip drive, a flash memory card, and/or a memory stick. Furthermore, the disk 1406 can include optical drives like, compact disk ROM (CD-ROM), a CD recordable drive (CD-R drive), a CD rewriteable drive (CD-RW drive) and/or a digital versatile ROM drive (DVD ROM). The memory 1404 can store processes 1414 and/or data 1416 , for example. The disk 1406 and/or memory 1404 can store an operating system that controls and allocates resources of the computer 1400 .
The bus 1408 can be a single internal bus interconnect architecture and/or other bus architectures. The bus 1408 can be of a variety of types including, but not limited to, a memory bus or memory controller, a peripheral bus or external bus, and/or a local bus. The local bus can be of varieties including, but not limited to, an industrial standard architecture (ISA) bUs, a microchannel architecture (MSA) bus, an extended ISA (EISA) bus, a peripheral component interconnect (PCI) bus, a universal serial (USB) bus, and a small computer systems interface (SCSI) bus.
The computer 1400 interacts with input/output devices 1418 via input/output ports 1410 . Input/output devices 1418 can include, but are not limited to, a keyboard, a microphone, a pointing and selection device, cameras, video cards, displays, and the like. The input/output ports 1410 can include but are not limited to, serial ports, parallel ports, and USB ports.
The computer 1400 can operate in a network environment and thus is connected to a network 1420 by a network interface 1412 . Through the network 1420 , the computer 1400 may be logically connected to a remote computer 1422 . The network 1420 can include, but is not limited to, local area networks (LAN), wide area networks (WAN), and other networks. The network interface 1412 can connect to local area network technologies including, but not limited to, fiber distributed data interface (FDDI), copper distributed data interface (CDDI), ethernet/IEEE 802.3, token ring/IEEE 802.5, and the like. Similarly, the network interface 1412 can connect to wide area network technologies including, but not limited to, point to point links, and circuit switching networks like integrated services digital networks (ISDN), packet switching networks, and digital subscriber lines (DSL).
Referring now to FIG. 15 , information can be transmitted between various computer components associated with controller scaling and parameterization described herein via a data packet 1500 . An exemplary data packet 1500 is shown. The data packet 1500 includes a header field 1510 that includes information such as the length and type of packet. A source identifier 1520 follows the header field 1510 and includes, for example, an address of the computer component from which the packet 1500 originated. Following the source identifier 1520 , the packet 1500 includes a destination identifier 1530 that holds, for example, an address of the computer component to which the packet 1500 is ultimately destined. Source and destination identifiers can be, for example, globally unique identifiers (guids), URLS (uniform resource locators), path names, and the like. The data field 1540 in the packet 1500 includes various information intended for the receiving computer component. The data packet 1500 ends with an error detecting and/or correcting field 1550 whereby a computer component can determine if it has properly received the packet 1500 . While six fields are illustrated in the data packet 1500 , it is to be appreciated that a greater and/or lesser number of fields can be present in data packets.
FIG. 16 is a schematic illustration of sub-fields 1600 within the data field 1540 ( FIG. 15 ). The sub-fields 1600 discussed are merely exemplary and it is to be appreciated that a greater and/or lesser number of sub-fields could be employed with various types of data germane to controller scaling and parameterization. The sub-fields 1600 include a field 1610 that stores, for example, information concerning the frequency of a known controller and a second field 1620 that stores a desired frequency for a desired controller that will be scaled from the known controller. The sub-fields 1600 may also include a field 1630 that stores a frequency scaling data computed from the known frequency and the desired frequency.
Referring now to FIG. 17 , an application programming interface (API) 1700 is illustrated providing access to a system 1710 for controller scaling and/or parameterization. The API 1700 can be employed, for example, by programmers 1720 and/or processes 1730 to gain access to processing performed by the system 1710 . For example, a programmer 1720 can write a program to access the system 1710 (e.g., to invoke its operation, to monitor its operation, to access its functionality) where writing a program is facilitated by the presence of the API 1700 . Thus, rather than the programmer 1720 having to understand the internals of the system 1710 , the programmer's task is simplified by merely having to learn the interface to the system 1710 . This facilitates encapsulating the functionality of the system 1710 while exposing that functionality. Similarly, the API 1700 can be employed to provide data values to the system 1710 and/or retrieve data values from the system 1710 .
For example, a proceSs 1730 that retrieves plant information from a data store can provide the plant information to the system 1710 and/or the programmers 1720 via the API 1700 by, for example, using a call provided in the API 1700 . Thus, in one example of the API 1700 , a set of application program interfaces can be stored on a computer-readable medium. The interfaces can be executed by a computer component to gain access to a system for controller scaling and parameterization. Interfaces can include, but are not limited to, a first interface 1740 that facilitates communicating controller information associated with PID production, a second interface 1750 that facilitates communicating plant information associated with PID production, and a third interface 1760 that facilitates communicating frequency scaling information generated from the plant information and the controller information.
The systems, methods, and objects described herein may be stored, for example, on a computer readable media. Media can include, but are not limited to, an ASIC, a CD, a DVD, a RAM, a ROM, a PROM, a disk, a carrier wave, a memory stick, and the like. Thus, an example computer readable medium can store computer executable instructions for one or more of the claimed methods.
What has been described above includes several examples. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the systems, methods, computer readable media and so on employed in scaling and parameterizing controllers. However, one of ordinary skill in the art may recognize that further combinations and permutations are possible. Accordingly, this application is intended to embrace alterations, modifications, and variations that fall within the scope of the appended claims. Furthermore, the preceding description is not meant to limit the scope of the invention. Rather, the scope of the invention is to be determined only by the appended claims and their equivalents.
While the systems, methods and so on herein have been illustrated by describing examples, and while the examples have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will be readily apparent to those skilled in the art. Therefore, the invention, in its broader aspects, is not limited to the specific details, the representative apparatus, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept. | Controller scaling and parameterization are described. Techniques that can be improved by employing the scaling and parameterization include, but are not limited to, controller design, tuning and optimization. The scaling and parameterization methods described here apply to transfer function based controllers, including PID controllers. The parameterization methods also applies to state feedback and state observer based controllers, as well as linear active disturbance rejection controllers. It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the application. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. | 6 |
SEQUENCE LISTING
[0001] 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. The ASCII-formatted sequence listing, created on Feb. 11, 2014, is named SBG-014-00US-sequences_ST25, and is 806 bytes in size.
FIELD OF THE INVENTION
[0002] The invention relates to analysis of genetic and genomic sequences.
BACKGROUND
[0003] Much information about a person's health is encoded in their DNA. Next-generation sequencing (NGS) technologies rapidly translate that information from its natural, biological format into files of sequence data that can be examined for disease-associated mutations and other features. However, as DNA sequencing technologies become faster, cheaper, and more accurate, the results produced by those sequencing technologies can become difficult to analyze.
[0004] It is now often the case that a researcher or medical professional will have to make sense of raw sequence data that is more complex than the linear sequence of “a gene” or even “a genome”. Most genomic sequencing produces millions of reads that must be assembled together in order to make sense of the data. Due to heterozygosity, somatic mutations, repeated genetic elements, structural variants, sequencing errors, or other factors, sequence reads can be assembled in many ways, some of which have little, or even misleading, informatics content. Moreover, genomic sequencing is often more complex than simply sequencing an individual's genome. For example, researchers will study whole populations of related subjects, or will need to compare those results from one study with those results from another. Unfortunately, comparing one set of results with another often requires data-limiting simplifications. For example, reads are often assembled and then reduced to a consensus sequence for comparison to a reference, thus potentially ignoring sources of heterogeneity within those reads.
[0005] Some attempts have been made to represent genetic information using a data structure known as a directed acyclic graph (DAG). However, while a DAG can potentially represent known instances of heterogeneity, simply having a DAG does not address the problem of what to do with numerous complex sets of sequence data.
SUMMARY
[0006] The invention provides methods for comparing one set of genetic sequences to another without discarding any information within either set or otherwise sacrificing the breadth of information within either set of sequences for the sake of making the comparison. The invention includes methods of aligning two or more DAGs in order to produce an aligned DAG. The aligned DAG is simply the aligned combination of two or more DAGs and is similar to any of the original DAGs except that the input to the aligned DAG is always two or more DAGs as opposed to linear sequence. The aligned DAG can further be aligned to other DAGs or other aligned DAGs as described below.
[0007] Methods of the invention are useful to obtain a best-scoring DAG alignment based on weighted scores for matches, mis-matches, and gaps and can find the best scoring alignment even where each of the input sequence data sets to be aligned is structured to represent numerous different nucleotides or sequences at numerous different locations along a genome, that is, where each input sequence set is a structured as a non-linear representation of a plurality of aligned sequences such as a genomic sequence DAG.
[0008] Methods of the invention are useful to store sets of genetic sequences as a sequence DAG. A sequence DAG may be used to represent any multi-plex set of related nucleic acid or protein sequences such as, for example, a multiple sequence alignment of related genes, an assembly of NGS reads, or two or more reference genomes. Furthermore, methods of the invention may be used to align one sequence DAG to another, wherein the resulting alignment can be represented as a sequence DAG that can potentially represent a full multiple sequence alignment among all of the individual sequences that contributed to one of the paths through one of the initial sequence DAGs.
[0009] DAG-to-DAG alignment is a natural choice for many urgent applications. It is appropriate wherever a set of genomic information consisting of more than one string needs to be compared to any non-linear reference. For example, a subpopulation DAG could be compared to a population DAG in order to compare the genetic features of that subpopulation to those of the population. Similarly, a cancer DAG could be compared to a species, population, subpopulation, or familial DAG. In view of the fact that the progression of cancer may be viewed as rapid, numerous mutations in the genome, a DAG representing certain types of cancers may give a better understanding not only of the cause of cancer but of the cancer itself.
[0010] In certain aspects, the invention provides a method for genomic analysis. The method includes representing a plurality of nucleic acids as a reference directed acyclic graph (DAG), wherein a DAG comprises nodes, each node comprising a string of one or more nucleotides, and edges defining connections among the nodes, and further wherein one or more of the nodes each represent more than one of the plurality of nucleic acids. The method further includes obtaining a second DAG representing a second plurality of nucleic acids and finding an optimally-scoring alignment between the second DAG and the reference DAG. The second DAG can be obtained from any suitable source such as, for example, sequence reads from a sample from a subject. The reference DAG may represent a plurality of alleles associated with a disease.
[0011] Preferably the steps are performed using a computer system comprising a processor coupled to a non-transitory memory having the reference DAG stored therein and further wherein the optimally-scoring alignment is stored as a final DAG in the non-transitory memory. A DAG may be stored as a computer file in which each node comprises a character string and a label and each edge comprises a pair of labels.
[0012] Finding the best-scoring alignments between a reference DAG and a second DAG may be done by initializing a matrix or matrices with the nucleotides of the first DAG on one side or and those of the second DAG on the other side. As the figures indicate, representing this two-dimensionally can be difficult, because each DAG is itself more than one-dimensional and those DAGs do not map easily onto linear sides of matrices. However, the equations described herein describe straightforward recursive relationships between the matrix elements. The matrix cell with the highest value is identified after that recursive process is complete, and a path through the matrix is identified ending at that cell (e.g., using Smith-Waterman-type “backtracking” techniques). This path indicates the optimally-scoring or best-scoring alignment between the second DAG and the reference DAG.
[0013] In some embodiments, at least one path through the reference DAG represents a sequence of a human chromosome. At least one path through the second DAG may represent an alternative sequence of the human chromosome. Homozygous loci in the sample may be represented using a single node in the second DAG and heterozygous loci in the sample are represented using different nodes in the second DAG. In certain embodiments, the second DAG represents a transcriptome from an organism and the reference DAG represents one or more genomes from organisms of a same species as the organism. In some embodiments, the reference DAG comprises a plurality of binary alignment map (BAM) entries that have been mapped to a first genomic reference and the second DAG comprises a second plurality of BAM entries that have been mapped to a second genomic reference.
[0014] Aspects of the invention provide a method of identifying chromosomal structural variants. The method includes obtaining a plurality of paired-end reads from a nucleic acid sample, each comprising an upstream pair member and a downstream pair member and characterized by an insert length approximating a number of nucleotides spanning a distance from an upstream end of the upstream pair member to a downstream end of the downstream pair member. The upstream pair member of each of the plurality of paired-end reads is mapped to a reference. A subset of the plurality of paired-end reads for which the upstream pair members map to the reference within a pre-defined cluster is found. For the subset of the plurality of paired-end reads, the downstream pair members are assembled into a DAG that represents one or more chromosomal structural variants within the sample.
[0015] In other aspects, the invention provides a method of identifying haplotypes. The method includes obtaining a plurality of sequence reads from a number k of diploid genomes, assembling the reads into a DAG representing optimally-scoring alignments among the sequence reads, and determining support for each of a plurality of paths through the DAG according to a number of reads consistent with a location in that path that is consistent with fewer reads than any other location in that path. A number of the paths meeting some pre-determined support criteria are identified as describing relevant haplotypes. In some embodiments, the pre-determined support criteria includes identifying a number n of paths for which the support meets a constraint and identifying the min(n, k) best-supported of the paths as the relevant haplotypes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 represents a read being compared to a DAG.
[0017] FIG. 2 shows the actual matrices that correspond to the comparison.
[0018] FIG. 3 illustrates a DAG that obtains from a first step in building a sequence DAG.
[0019] FIG. 4 shows how an initial DAG is built up by alignment.
[0020] FIG. 5 shows a DAG continuing to grow.
[0021] FIG. 6 illustrates a sequence DAG that is nearly complete.
[0022] FIG. 7 depicts the complete DAG
[0023] FIG. 8 diagrams a method of DAG-to-DAG alignment
[0024] FIG. 9 shows a prior art approach to detecting structural variants.
[0025] FIG. 10 illustrates a computer system according to embodiments of the invention.
DETAILED DESCRIPTION
[0026] Embodiments of the invention provide for the alignment of one sequence DAG to another sequence DAG. A DAG is a mathematical data structure that may be represented as a graph, but that is not necessarily ever instantiated as a visible graph. A DAG is a data structure that has nodes connected by directed edges, wherein no single path through the DAG traverses the same node more than once and thus does not include any cycles. “DAG” can refer to a graph, the underlying data structure, or both, and as used herein, “sequence DAG” refers to a DAG representing biological sequences. A sequence DAG may be a record stored in a non-transitory, computer-readable medium that includes nodes connected by edges, in which each node includes a string of one or more nucleotide characters with a 5′-3′ directionality and each edge extends from a 3′ end of the character string of one node to a 5′ end of a string of another node. At least one node will be a source in that it has no edges connected to the 5′ end of its character string. At least one node will be a sink in that it has no edges connected to the 3′ end of its character string. What characters are permitted may depend on the embodiment or implementation, and in some embodiments, the permitted characters include the IUPAC nucleotide codes (either A, T, C, and G, with or without U or N, or the complete set of IUPAC ambiguity codes).
1. Alignments
[0027] The invention provides methods for aligning one or more sequence DAGs to one another. Alignment generally involves placing one sequence along another sequence, gaps may be introduced along each sequence, scoring how well the two sequences match, and preferably repeating for various position along one or more of the sequences. The best-scoring match is deemed to be the alignment and represents an inference about the historical relationship between the sequences. Some analysis projects may seek an optimal scoring alignment that is not also a highest scoring alignment, and methods of the invention may be used to find the optimally scoring alignment. For example, where gene duplication has created copies of a gene that descend side by side during the history of an organism, (e.g., alpha and beta hemoglobin) the genes may be called paralogous genes. Fitch, 1970, Distinguishing homologous from analogous proteins, Systematic Zoology 19:99-113. A researcher studying two paralogous genes in an organism's genome may obtain sequence reads from one of those genes. The researcher may wish to compare a sequence read DAG from the one gene to a genomic DAG that represents a plurality of known genomes for that organism. In some instances, the read DAG may have a higher-scoring alignment to the second, paralogous gene (e.g., due to mutations in the researcher's sample) than to the one gene. In that sense, the researcher has a priori information that the alignment of the read DAG to the one gene in the genomic DAG is the optimal alignment, even though it is not the highest-scoring or best-scoring alignment. Methods of the invention may be used to find that optimal alignment by excluding the other alignment results from consideration. Thus the invention provides methods that may be used to find an alignment between two or more sequence DAG. In some embodiments, the resulting aligned DAG will represent an optimal alignment. That optimal alignment may be a best-scoring DAG matrix alignment produced by a combination of the two sequence-DAGs. The best-scoring DAG alignment may be determined by the mathematical construct as described herein, representing the optimal path through a matrix of similarity scores.
[0028] In a pairwise alignment, a base in one sequence alongside a non-matching base in another indicates that a substitution mutation has occurred at that point. Similarly, where one sequence includes a gap alongside a base in the other sequence, an insertion or deletion mutation (an “indel”) may be inferred to have occurred.
[0029] In some embodiments, scoring an alignment of a pair of nucleic acid sequences involves setting values for the probabilities of substitutions and indels. When individual bases are aligned, a match or mismatch contributes to the alignment score by a score or a penalty, which could be, for example, a match score of 1 for a match and a mismatch penalty of −0.33 for a mismatch. An indel deducts from an alignment score by a gap penalty, which could be, for example, −1. Scores and penalties can be based on empirical knowledge or a priori assumptions about how sequences evolve. Their values affects the resulting alignment. Particularly, the relationships among score and penalty values influence whether substitutions or indels will be favored in the resulting alignment. Additional helpful discussion may be found in Rodelsperger, 2008, Syntenator: Multiple gene order alignments with a gene-specific scoring function, Alg Mol Biol 3:14; Yanovsky, et al., 2008, Read mapping algorithms for single molecule sequencing data, Procs of the 8th Int Workshop on Algorithms in Bioinformatics 5251:38-49; Hein, 1989, A new method that simultaneously aligns and reconstructs ancestral sequences for any number of homologous sequences, when phylogeny is given, Mol Biol Evol 6(6):649-668; Schwikowski & Vingron, 2002, Weighted sequence graphs: boosting iterated dynamic programming using locally suboptimal solutions, Disc Appl Mat 127:95-117, the contents of each of which are incorporated by reference.
[0030] Stated formally, a pairwise alignment represents an inferred relationship between two sequences, x and y. For example, in some embodiments, a pairwise alignment A of sequences x and y maps x and y respectively to another two strings x′ and y′ that may contain spaces such that: (i) |x′|=|y′|; (ii) removing spaces from x′ and y′ should get back x and y, respectively; and (iii) for any i, x′[i] and y′[i] cannot be both spaces.
[0031] A gap is a maximal substring of contiguous spaces in either x′ or y′. Pairwise alignment A can include the following three kinds of regions: (i) matched pair (e.g., x′[i]=y′[i]; (ii) mismatched pair, (e.g., x′[i]≠y′[i] and both are not spaces); or (iii) gap (e.g., either x′[i . . . j] or y′[i . . . j] is a gap). In certain embodiments, only a matched pair has a high positive score a. In some embodiments, a mismatched pair generally has a negative score b and a gap of length r also has a negative score g+rs where g, s<0. For DNA, one common scoring scheme (e.g. used by BLAST) makes score a=1, score b=−3, g=−5 and s=−2. The score of the alignment A is the sum of the scores for all matched pairs, mismatched pairs and gaps. The alignment score of x and y can be defined as the maximum score among all possible alignments of x and y.
[0032] In some embodiments, any pair has a score a defined by a 4×4 matrix B of scores/penalties. For example, B[i,i]=1 and 0<B(i,j)i<>j<1 is one possible scoring system. For instance, where a transition is thought to be more biologically probable than a transversion, matrix B could include B[C,T]=0.7 and B[A,T]=0.3, or any other set of values desired or determined by methods known in the art.
[0033] Alignment according to some embodiments of the invention generally involves—for sequence Q (query) having m characters and a reference genome T (target) of n characters—finding and evaluating possible local alignments between Q and T. For any 1≦i≦n and 1≦j≦m, the largest possible alignment score of T[h . . . i] and Q[k . . . j], where h≦i and k≦j, is computed (i.e. the best alignment score of any substring of T ending at position i and any substring of Q ending at position j). This can include examining all substrings with cm characters, where c is a constant depending on a similarity model, and aligning each substring separately with Q. Each alignment is scored, and the alignment with the preferred score is accepted as the alignment. One of skill in the art will appreciate that there are exact and approximate algorithms for sequence alignment. Exact algorithms will find the highest scoring alignment, but can be computationally expensive. Two well-known exact algorithms are Needleman-Wunsch (J Mol Biol, 48(3):443-453, 1970) and Smith-Waterman (J Mol Biol, 147(1):195-197, 1981; Adv. in Math. 20(3), 367-387, 1976). A further improvement to Smith-Waterman by Gotoh (J Mol Biol, 162(3), 705-708, 1982) reduces the calculation time from O(m2n) to O(mn) where m and n are the sequence sizes being compared and is more amendable to parallel processing. In the field of bioinformatics, it is Gotoh's modified algorithm that is often referred to as the Smith-Waterman algorithm.
[0034] Smith-Waterman-type algorithms align linear sequences by rewarding overlap between bases in the sequences, and penalizing gaps between the sequences. Smith-Waterman also differs from Needleman-Wunsch, in that Smith-Waterman does not require the shorter sequence to span the string of letters describing the longer sequence. That is, Smith-Waterman does not assume that one sequence is a read of the entirety of the other sequence. Furthermore, because Smith-Waterman is not obligated to find an alignment that stretches across the entire length of the strings, a local alignment can begin and end anywhere within the two sequences. Smith-Waterman algorithms, and implementations thereof, are described in more detail in U.S. Pat. No. 5,701,256 and U.S. Pub. 2009/0119313, both herein incorporated by reference in their entirety.
[0035] Smith-Waterman type algorithms may be used to perform a pairwise alignment of two sequences a and b of length n and m by first calculating values for entries h[i,j] in an n×m matrix H of similarity (or distance) scores and then finding a trace through that matrix according to the steps described below. First, the matrix is initialized by assigning h[i,0]=h[0,j]=0, for 0≦i≦n and 0≦j≦m. Note that i and j are indices of a and b so that a[i] is the ith nucleotide in a.
[0036] Then, for each remaining entry h[i,j], the neighbors to the left, above, and to the above-left of that entry are evaluated to find the highest scoring one of those entries. In a two dimensional matrix (e.g., during pairwise alignment), those three cells to the left, above, and diagonally to the left and above h[i,j] would be h[i−1,j], h[i,j−1], and h[i−1,j−1].
[0037] An association is recorded between that entry h[i,j] and the highest valued of h[i−1,j], h[i,j−1], and h[i−1,j−1]. A value is calculated for h[i,j] based on the value of that associated entry. The association can be thought of as a pointer from entry h[i,j] to its highest-valued neighbor, and this pointer will be “looked at” later, when it used to find a trace through the matrix. The value assigned to h[i,j] is:
[0000] max{ h[i− 1, j− 1]+ s ( a[i],b[j ]), h[i− 1, j]−W,h[i,j− 1]− W, 0}
[0038] In the equations above, s(a[i],b[j]) represents either a match bonus (when a[i]=b[j]) or a mismatch penalty (when a[i]≠b[j]), and W represents a penalty for gap in either a or b. Gap penalty W may preferably include an opening component and an extension component, discussed later.
[0039] Once values have been assigned for every entry h[i,j] in H, a trace is found through the matrix by the following steps. First, the highest-valued entry h[i,j] is identified. Then—remembering that each entry is associated with one upstream neighbor—entries in H are traced sequentially from the highest-valued entry following the associations, or “pointers”, until a zero entry is reached. The resulting trace will originate at the highest-valued entry and extend “back” (i.e., towards h[0,0]) to its terminus at the first zero entry encountered by following the pointers. That trace (sometimes called a traceback in the literature) indicates the optimally-scoring alignment between the sequences a and b. That is, the optimally-scoring alignment can be read by writing out the indices of each entry in the trace in their order within the trace and supplying a “-” character where the trace extends off-diagonal, and then using the indices as indices of a and b to retrieve the corresponding nucleotide characters from a and b. Thus if a trace extends through h[3,3], h[4,4], h[4,5], h[4,6], h[5,7], the paired indices will be:
[0040] 3 4 - - 5
[0041] 3 4 5 6 7
[0042] Smith-Waterman type alignment may be employed using dynamic programming. This dynamic programming technique employs tables or matrices to preserve match scores and avoid re-computation for successive cells.
[0043] To formalize the foregoing description for programming, and to give an example set of values for the bonuses and penalties, the following steps are given. Note that in the above, a single gap penalty was used. In the below, separate insertion and deletion penalties are tracked. Either approach may be used and one of skill in the art may choose one over the other for extrinsic reasons such as a priori knowledge of likelihoods of certain sequence evolution events.
[0044] Each element of a string is indexed with respect to a letter of the sequence, that is, if S is the string ATCGAA, S[1]=A.
[0045] For a matrix B, entries B[j,k] are given in equation (2) below:
[0000] B[j,k ]=max( p[j,k],i[j,k],d[j,k], 0) (for 0< j≦m, 0< k≦n ) (2)
[0046] The arguments of the maximum function, B[j,k], are outlined in equations (3)-(5) below, wherein MISMATCH_PENALTY, MATCH_BONUS, INSERTION_PENALTY, DELETION_PENALTY, and OPENING_PENALTY are all constants, and all negative except for MATCH_BONUS. The match argument, p[j,k], is given by equation (3), below:
[0000] p[j,k ]=max( p[j− 1, k− 1], i[j− 1, k− 1], d[j− 1, k− 1])+MISMATCH_PENALTY, if S[j]≠A[k ]=max( p[j− 1, k− 1], i[j− 1, k− 1], d[j− 1, k− 1])+MATCH_BONUS, if S[j]=A[k] (3)
[0047] the insertion argument i[j,k], is given by equation (4), below:
[0000] i[j,k] =max( p[j− 1 ,k ]+OPENING_PENALTY, i[j− 1 ,k],d[j− 1 ,k]+ OPENING_PENALTY)+INSERTION_PENALTY (4)
[0048] and the deletion argument d[j,k], is given by equation (5), below:
[0000] d[j,k] =max( p[j,k− 1]+OPENING_PENALTY, i[j,k− 1]+OPENING_PENALTY, d[j,k− 1])+DELETION_PENALTY (5)
[0049] For all three arguments, the [0,0] element is set to zero to assure that the backtrack goes to completion, i.e., p[0,0]=i[0,0]=d[0,0]=0.
[0050] The scoring parameters may be adjusted according to the project. One example of the scoring parameter settings (Huang, Chapter 3: Bio-Sequence Comparison and Alignment, ser. Curr Top Comp Mol Biol. Cambridge, Mass.: The MIT Press, 2002) for DNA would be:
[0051] MATCH_BONUS: 10
[0052] MISMATCH_PENALTY: −20
[0053] INSERTION_PENALTY: −40
[0054] OPENING_PENALTY: −10
[0055] DELETION_PENALTY: −5
[0056] The relationship between the gap penalties (INSERTION_PENALTY, OPENING_PENALTY) above help limit the number of gap openings, i.e., favor grouping gaps together, by setting the gap insertion penalty higher than the gap opening cost. Of course, alternative relationships between MISMATCH_PENALTY, MATCH_BONUS, INSERTION_PENALTY, OPENING_PENALTY and DELETION_PENALTY are possible.
2. Sequence DAG Alignments
[0057] The foregoing describes a formalism of a Smith-Waterman type alignment that is conducive to implementation by dynamic programming. One benefit of the invention includes the insight that the alignment algorithm, thus formalized, may be extended to a non-linear sequence structure such as a sequence DAG. Such an extended implementation may be referred to as a multi-dimensional Smith-Waterman type alignment. Such multi-dimensional algorithms of the invention provide for a “look-back” through a multi-dimensional space that includes multiple pathways and multiple nodes. The multi-dimensional algorithm identifies the maximum score at each position on the DAG (e.g., the reference sequence construct). In fact, by looking “backwards” at the preceding positions, it is possible to identify the optimum alignment across a plurality of possible paths.
[0058] A sequence DAG may be stored as a list of nodes and edges. One way to do this is to create a text file that includes all nodes, with an ID assigned to each node, and all edges, each with the node ID of starting and ending node. Thus, for example, were a DAG to be created for two sentences, “See Jane run,” and “Run, Jane run,”, a case-insensitive text file could be created. Any suitable format could be used. For example, the text file could include comma-separated values. Naming this DAG “Jane” for future reference, in this format, the DAG “Jane” may read as follows: 1 see, 2 run, 3 jane, 4 run, 1-3, 2-3, 3-4. One of skill in the art will appreciate that this structure is easily applicable to the sequences represented in FIGS. 1 and 7 , for example, and the accompanying discussion below.
[0059] In certain embodiments, a DAG is stored as a table representing a matrix (or an array of arrays or similar variable structure representing a matrix) in which the (i,j) entry in the matrix denotes whether node i and node j are connected. For the DAG to be acyclic simply requires that all non-zero entries be above the diagonal (assuming indices are correctly ordered). In a binary case, a 0 entry represents that no edge is exists from node i to node j, and a 1 entry represents an edge from i to j. One of skill in the art will appreciate that a matrix structure allows values other than 0 to 1 to be associated with an edge. For example, any entry may be a numerical value indicating a weight, or a number of times used, reflecting some natural quality of observed data in the world. A matrix can be written to a text file as a table or a linear series of rows (e.g., row 1 first, followed by a separator, etc.), thus providing a simple serialization structure.
[0060] One useful way to serialize a matrix DAG would be to use comma-separated values for the entries, after defining the nodes. Using this format, the DAG “Jane” would include the same node definitions as for above, followed by matrix entries. This format could read as:
[0061] 1 see, 2 run, 3 jane, 4 run
[0062] ,,1,\,,1,\,,,1\,,,
[0063] where zero (0) entries are simply omitted and ‘\’ is a newline character.
[0064] Embodiments of the invention include storing a sequence DAG in a language built with syntax for graphs. For example, The DOT Language provided with the graph visualization software package known as Graphviz provides a data structure that can be used to store a DAG with auxiliary information and that can be converted into graphic file formats using a number of tools available from the Graphviz web site. Graphviz is open source graph visualization software. Graph visualization is a way of representing structural information as diagrams of abstract graphs and networks. It has important applications in networking, bioinformatics, software engineering, database and web design, machine learning, and in visual interfaces for other technical domains. The Graphviz programs take descriptions of graphs in a simple text language, and make diagrams in useful formats, such as images and SVG for web pages; PDF or Postscript for inclusion in other documents; or display in an interactive graph browser.
[0065] In an intermediate extension of Smith-Waterman type alignments, a sequence string is aligned to a sequence DAG, and a discussion of this will aid in understanding and implementing a full DAG-to-DAG alignment.
[0066] For aligning a string to a DAG, let S be the string being aligned, and let D be the directed acyclic graph to which S is being aligned. The elements of the string, S, are bracketed with indices beginning at 1. Thus, if S is the string ATCGAA, S[1]=A, S[4]=G, etc.
[0067] In certain embodiments, for the DAG, each letter of the sequence of a node will be represented as a separate element, d. A predecessor of d is defined as:
[0068] (i) If d is not the first letter of the sequence of its node, the letter preceding d in its node is its (only) predecessor;
[0069] (ii) If d is the first letter of the sequence of its node, the last letter of the sequence of any node (e.g., all exons upstream in the genome) that is a parent of d's node is a predecessor of d.
[0070] The set of all predecessors is, in turn, represented as P[d].
[0071] In order to find the “best” alignment, the algorithm seeks the value of M[j,d], the score of the optimal alignment of the first j elements of S with the portion of the DAG preceding (and including) d. This step is similar to finding Hi,j in equation 1 above. Specifically, determining M[j,d] involves finding the maximum of a, i, e, and 0, as defined below:
[0000] M[j,d ]=max{ a,i,e, 0} (6)
where e=max{M[j, p*]+DELETE_PENALTY} for p* in P[d] i=M[j−1, d]+INSERT_PENALTY a=max{M[j−1, p*]+MATCH_SCORE} for p* in P[d], if S[j]=d; max{M[j−1, p*]+MISMATCH_PENALTY} for p* in P[d], if S[j]≠d
[0077] As described above, e is the highest of the alignments of the first j characters of S with the portions of the DAG up to, but not including, d, plus an additional DELETE_PENALTY. Accordingly, if d is not the first letter of the sequence of the node, then there is only one predecessor, p, and the alignment score of the first j characters of S with the DAG (up-to-and-including p) is equivalent to M[j,p]+DELETE_PENALTY. In the instance where d is the first letter of the sequence of its node, there can be multiple possible predecessors, and because the DELETE_PENALTY is constant, maximizing [M[j, p*]+DELETE_PENALTY] is the same as choosing the predecessor with the highest alignment score with the first j characters of S.
[0078] In equation (6), i is the alignment of the first j−1 characters of the string S with the DAG up-to-and-including d, plus an INSERT_PENALTY, which is similar to the definition of the insertion argument in the pairwise case.
[0079] Additionally, a is the highest of the alignments of the first j characters of S with the portions of the DAG up to, but not including d, plus either a MATCH_SCORE (if the jth character of S is the same as the character d) or a MISMATCH_PENALTY (if the jth character of S is not the same as the character d). As with e, this means that if d is not the first letter of the sequence of its node, then there is only one predecessor, i.e., p. That means a is the alignment score of the first j−1 characters of S with the DAG (up-to-and-including p), i.e., M[j−1,p], with either a MISMATCH_PENALTY or MATCH_SCORE added, depending upon whether d and the jth character of S match. In the instance where d is the first letter of the sequence of its node, there can be multiple possible predecessors. In this case, maximizing {M[j, p*]+MISMATCH_PENALTY or MATCH_SCORE} is the same as choosing the predecessor with the highest alignment score with the first j−1 characters of S (i.e., the highest of the candidate M[j−1,p*] arguments) and adding either a MISMATCH_PENALTY or a MATCH_SCORE depending on whether d and the jth character of S match.
[0080] Again, as in the SW algorithm, the penalties, e.g., DELETE_PENALTY, INSERT_PENALTY, MATCH_SCORE and MISMATCH_PENALTY, can be adjusted to encourage alignment with fewer gaps, etc.
[0081] As described in the equations above, the algorithm finds the optimal alignment for a sequence to a DAG by calculating not only the insertion, deletion, and match scores for that element, but looking backward (against the direction of the DAG) to any prior nodes on the DAG to find a maximum score. Thus, the algorithm is able to traverse the different paths through the DAG. The backtraces follow the best alignment and extend toward the origin of the graph, and identify the most likely alignment within a high degree of certainty.
[0082] Implementation of the disclosed algorithm is exemplified in FIG. 1 , where a sequence “ATCGAA” is aligned against a DAG that represents a reference sequence TTGGATATGGG (SEQ ID NO: 1) and a known insertion event TTGGAT CGAATT ATGGG (SEQ ID NO: 2), where the insertion is underlined.
[0083] FIG. 1 shows a pictorial representation of the read (“ATCGAA”) being compared to the DAG. The top area of FIG. 1 presents a reference sequence TTGGATATGGG (SEQ ID NO: 1) and a known insertion event TTGGAT CGAATT ATGGG (SEQ ID NO: 2) (here, the insertion is underlined). The bottom area of FIG. 1 shows the alignment constructed using a DAG. In the depicted DAG, SEQ ID NOS. 1 and 2 can both be read by reading from the 5′ end of the DAG to the 3′ end of the DAG, albeit along different paths. The sequence read is shown as aligning to the upper path as depicted.
[0084] FIG. 2 shows the actual matrices that correspond to the comparison. Like the Smith-Waterman technique, the illustrated algorithm of the invention identifies the highest score and performs a backtrack to identify the proper location of the read. FIGS. 1 and 2 also highlight that the invention produces an actual match for the string against the construct. In the instances where the sequence reads include variants that were not included in the DAG, the aligned sequence will be reported out with a gap, insertion, etc.
[0085] One sequence DAG can be aligned to another sequence DAG to generate an aligned DAG by generalizing the foregoing in a method that includes first calculating values for entries in an array of pairwise match scores between characters from the respective sequence DAGs and then tracing along series of adjacent, associated elements in that array to find best-scoring alignments between paths through the respective DAGs. All of those resulting best-scoring alignments can be presented or stored as an aligned DAG. The aligned DAG is the aligned combination of the two sequence DAGs and is structurally similar to any of the original DAGs except that the input to the aligned DAG is always two or more DAGs as opposed to linear sequence. The aligned DAG can further be aligned to other DAGs or other aligned DAGs as described below
[0086] The algorithmic modifications one must apply to the string-to-DAG algorithm in order to get a DAG-to-DAG algorithm are analogous to those applied to the string-to-string algorithm in order to get a string-to-DAG algorithm. In that case, we replaced terms such as i−1, where i represents an index, with P[i], where P[i] represents all immediate predecessors of the node with index i. One way to think about the modification is that finding the character with location i−1 in a string is a special case of picking out the set of predecessors: in a (linear) string, there is only one predecessor to the location with index i, and that is the location with index i−1, so insofar as a dynamic programming algorithm requires the consideration of some value for all predecessors of a location with index i, we can simply examine that value for the location with index i−1.
[0087] Considering the string-to-DAG equations as they appear above, we notice that various “j−1” terms, where j represents the index of a location in a string, still appear. Just as we moved from i−1 to P[i] in order to get the full set of predecessors in a DAG, we need to move from j−1 to P[j] to get the full set of predecessors of the object that is being aligned to the DAG, since this is no longer a string but itself a DAG. Thus, for example, we replace the e-term that is currently:
[0088] e=max{M[j,p*]+DELETE_PENALTY} for p* in P[d]
[0089] with:
[0090] e=max{M[p*, p**]+DELETE_PENALTY} for p* in P[d] and p** in P[d′]
[0091] Other terms are to be modified analogously, so that we have:
[0092] M[j,d]=max{a,i,e,0}
where e=max{M[p*, p**]+DELETE_PENALTY} for p* in P[j] and p** in P[d] i=max{M[p*, d]+INSERT_PENALTY} for p* in P[j] a=max{M[p*, p**]+MATCH_SCORE} for p* in P[j] & p** in P[d], if S[j]=d; max{M[p*, p**]+MISMATCH_PENALTY} for p* in P[j] and p** in P[d], if S[j]≠d
[0098] Although it is common to consider alignments of one string to another, and although we have shown how to generalize this process by replacing strings with DAGs, most people think of a process or result, not an object, when they speak of “alignments.” We observe, however, that the output of an alignment process, because it contains information about the relationship of one genetic item to another, can be represented not only as a located string or a compact idiosyncratic gapped alignment report (CIGAR) string, e.g., a CIGAR string in a BAM format file, but also as a DAG. For discussion of file formats, see Li, et al., 2009, The Sequence Alignment/Map format and SAMtools, Bioinformatics 25(16):2078-9 and Li et al., 2009, SOAP2: an improved ultrafast tool for short read alignment, Bioinformatics 25(15):1966-7, both incorporated by reference.
[0099] Because DAG-to-DAG alignment is possible, and because alignments can be viewed as DAGs, it is possible to align alignments to alignments. A set of BAM entries, for example, can be converted to DAGs and aligned to each other. Indeed, BAMs that have been generated relative to different references can be aligned against each other. Given the quantity of existing BAM files and the variety of references to which those files correspond, the ability to directly compare entries from BAMs with different references would be valuable, and these techniques remove barriers to our gaining that ability.
[0100] One can convert a BAM entry to a DAG by using the relevant reference and the CIGAR string for the given entry, because BAM sequence entries, CIGAR strings, and references—taken together—contain enough information to construct a DAG representing the alignment. With reference to Table 1 of Li, et al., 2009, The Sequence Alignment/Map format and SAMtools, Bioinformatics 25(16):2078-9, we see that the fourth mandatory field in the SAM format is POS, 1-Based leftmost POSition of clipped alignment.
[0101] Suppose that in a given BAM entry, we have in the SEQ field:
[0000]
(SEQ ID NO: 3)
GATTACACATGATTACATGACTGACCATTCCAT
[0102] The POS field tells us to look at position 1,525,334 in the reference, where we find:
[0000]
(SEQ ID NO: 4)
GAGTACAGATTACATGACTGACGGAGCATTACATCT . . .
[0103] In the CIGAR field, we find:
[0104] M7I3M15D4M8
[0105] We begin by examining the first seven characters of each sequence, because those correspond to portions that aligned to each other. Note that this does not entail that there are no mismatches:
[0000]
GATTACA
GAGTACA
[0106] We see that there is a mismatch in position 3.
[0107] FIG. 3 illustrates the DAG that is produced from a first step in building a sequence DAG. The “I3” portion of the CIGAR string indicates an insertion of three bases, so we can continue. FIG. 4 shows the DAG that represents a DAG as it grows. The “M15” indicates that the next fifteen characters of each string are aligned as a group. These indeed match, so we continue. FIG. 5 illustrates the DAG resulting from this step. The “D4” indicates that the next four bases from the reference are deleted, leading to the DAG shown in FIG. 6 . FIG. 6 illustrates a sequence DAG as it is being built. Finally, the last eight bases are treated as an aligned unit, and we find one mismatch. This produces our final DAG, shown in FIG. 7 . FIG. 7 depicts the complete DAG representing the alignment described by the hypothetical BAM entry.
[0108] That completed DAG as depicted in FIG. 7 is an example of a sequence DAG. The sequence DAG is created in a way that reflects the scoring given by a Smith-Waterman-type alignment algorithm and the sequence DAG can further be aligned to another sequence DAG.
[0109] FIG. 8 diagrams a method of DAG-to-DAG alignment according to embodiments of the invention. In general, the method includes the following steps.
[0110] Represent 803 a plurality of nucleic acids as a reference directed acyclic graph (DAG), wherein a DAG comprises nodes, each node comprising a string of one or more nucleotides, and edges defining connections among the nodes, and further wherein one or more of the nodes each represent more than one of the plurality of nucleic acids.
[0111] Obtain 807 a second DAG representing a second plurality of nucleic acids. Initialize 813 a matrix of similarities between nucleotides in the reference DAG and nucleotides in the second DAG by setting all edge entries to be zero, wherein an edge entry is an entry with no more than 1 non-zero index.
[0112] For each non-edge entry, associate that entry with a highest-value upstream neighbor entry of that entry and calculate 819 a value for that entry with a value based on the highest-value upstream neighbor entry, wherein an upstream neighbor entry has indices that each differ by −1 or 0, at least one index differing by −1, from the corresponding indices of that entry being populated.
[0113] Identify 831 a traceback path through the matrix that originates at the entry with the highest value and traces sequentially through each associated highest-value upstream neighbor until a zero entry is met at which zero entry the path terminates, wherein the identified path indicates the optimally-scoring alignment between the second DAG and the reference DAG.
[0114] Find an optimally-scoring alignment between the second DAG and the reference DAG. The alignment of one sequence DAG to another, as described, proceeds through the use of a matrix of similarities (or distances) and produces an aligned DAG. In that sense, the aligned DAG may be referred to as a “DAG matrix alignment” and so may the procedure of aligning sequences, sequence DAGs, or a combination thereof through the use of a similarity matrix to produce a DAG of aligned sequences may be referred to as performing a DAG matrix alignment.
[0115] One feature of the invention that is helpful to recognize is that methods of the invention may be used to find an alignment between two or more sequence DAGs and, depending on the nature or objectives of the work being done, the obtained alignment may be, but need not be, the “highest scoring” alignment nor even an optimally-scoring alignment. For example, some researchers may calculate both a similarity and a distance score by supplying different match and mismatch penalties. Since distance is a measure of a number of differences, and similarity is a measure of (roughly) a number of matches, the sign of the score would change depending on which is calculated. Further, where the two sequences TGC and TCC have certain a similarity score and a certain distance score, the two sequences TAACTAGC and TAACTACC would have the same distance score but a much higher similarity score.
3. Local Heuristic Assembly
[0116] A related but distinct innovation is “local heuristic assembly.” This process could be used to solve a persistent problem in the analysis of short reads: that of inferring the sequences of repetitive regions, tandem duplications, indels, and other structural variants.
[0117] There are two major obstacles to such inference. First, structural variants are so large that reads are simply thrown away as unalignable rather than recognized as arising from a certain region. Second, repetitive regions will align so well to many locations that it can be difficult to know which of those many locations corresponds to the real origin of the read. These obstacles are somewhat independent; each can occur without the other. Many structural variants are, however, repetitive regions, and many repetitive regions are likely candidates for being inserted or deleted in one sample relative to another (which is why they are repetitive in the first place).
[0118] The invention provides systems and methods for inferring the sequences of repetitive regions, tandem duplications, indels, and other structural variants based on paired-end data. Methods of the invention include aligning a plurality of paired-end reads to the reference, identifying a set of unaligned reads from the plurality of paired-end reads that did not align to the reference according to some criterion, and—for the set of unaligned reads—finding clusters of those unaligned paired-end reads for which a portion of reads map to the same part of the genome.
[0119] Any suitable method may be used find the clusters. Once one has mapped the beginnings of (paired-end) reads as far as they can be mapped, and associated those beginnings-of-reads with genomic locations, any known clustering method could in theory be used to sort those into clusters. In practice, it will likely be more reasonable simply to search for windows of R base pairs in which sufficiently many reads map. (We might take R to be equal to read length of a given set of short reads.) Clusters, in cases both of split reads and read-pairs, are discussed and illustrated in Stewart, et al., 2011, A comprehensive map of mobile element insertion polymorphisms in humans, PLoS Genetics 7(8):1-19, incorporated by reference.
[0120] FIG. 9 , reproduced from FIG. 1 in Stewart, et al., 2011, A comprehensive map of mobile element insertion polymorphisms in humans, PLoS Genetics 7(8):1-19, illustrates a prior art method for the detection of non-reference mobile element inserts (MEI). That method can use a read-pair constraint (RP) method applied to Illumina paired-end short read data and a split-read (SR) method applied to the longer read data from Roche/454 pyrosequencing. FIG. 9 shows the detection signatures and examples of event displays by RP detection. Candidate MEI events were formed as clusters of supporting fragments. A limitation specific to RP detection arises from annotated elements within a characteristic read pair fragment length of candidate MEI. Read pairs spanning from a uniquely mapped anchor into an annotated mobile element with a fragment length consistent with the given library fragment length distribution are characteristic of the reference allele and are not evidence for non-reference MEI.
[0121] FIG. 9 shows a prior art RP signature for of non-reference MEI detection. The RP signature consists of Illumina read pairs spanning into the element from each side of the insertion. The RP event display shows a heterozygous Alu insertion allele on chromosome 22 from a pilot dataset. Fragment mapping quality is shown on the vertical scale. Horizontal lines show read pairs uniquely mapped at both ends with a mapped fragment length consistent with the sequence library; the short lines at the outer ends of the arc-shaped lines are read pairs spanning into an Alu sequence from the 5′ and 3′ ends. The central vertical line is the position of the insertion. Thick lines near the top show annotated Alu positions. Thus, FIG. 8 illustrates a clusters of paired-end reads for which a portion of reads map to the same part of the genome for the RP case. Clusters may also be found in the SR case or in other contexts.
[0122] For each cluster, methods include filtering the reads so that the mapped and unmapped portions are at least a base pairs long, where a is a constant chosen beforehand (it might be reasonable to choose a=10) and sorting the unmapped portions according to their expected left-to-right (where ‘leftness’ corresponds to smaller indices and ‘rightness’ greater indices according to some indexing scheme) positions. This can be deduced from the read length, the insert size, and the length of the mapped portions.
[0123] As used herein, insert size is generally taken to refer to length of a nucleic acid molecule being sequenced. Thus an insert size may be, for example, 500 base pairs, with a read length of 100 base pairs. Then the distance between the reads is approximately 300 base pairs, so that if the mapped portion is greater than 100 base pairs, the expected starting position of the yet-to-be-mapped portion is (the starting position of the mapped portion+100+300+(the length of the mapped portion−100)), which equals (the starting position of the mapped portion+300+the length of the mapped portion). If the mapped portion is shorter than the sequence length, there figure to be two unmapped portions, one of which begins at (the starting position of the mapped portion+the length of the mapped portion) and the other of which begins at (the starting position of the mapped portion+100+300), which equals (the starting position of the mapped portion+400). It is recognized that in some instances in the literature, “insert size” is used to refer to the space between reads. However, method described herein are equally applicable regardless of how “insert size” is used by making the appropriate adjustments in language usage.
[0124] Methods further include, for each cluster taking the first (“first” according to the sorting procedure, that is) unmapped portion and consider it as a reference object. Although it is a string, take it to be a (flat) DAG. Call it R.
[0125] For each remaining unmapped read-portion, in sorted order: align that read-portion to R; create a DAG representing that alignment; and update R to be the DAG created in the preceding step.
[0126] The result is a raw local assembly—a DAG representing the region about which the original alignment process did not give information. Therefore, this process makes important improvements over the status quo. It will give accurate sequence information about indels and structural variants that existing tools do not resolve or altogether ignore. One can further refine this assembly DAG into haplotypes.
4. Applications to Haplotying
[0127] By haplotype we mean here set of nearby variants inherited (usually) together and able to be considered as a unit. A process of determining haplotypes in a sample can be used along with the process described above, and any related process whereby many reads (or alignments) are sequentially aligned to a reference object, which thereby accumulates information.
[0128] Note first that haplotypes can be represented as paths through a DAG. A process of determining relevant haplotypes is therefore expressible as a process of determining relevant paths through a DAG.
[0129] The invention provides systems and methods for determining relevant haplotypes from a sequence DAG. Methods include aligning reads to a DAG and tracking how many reads are consistent with each location within the DAG and defining the support of a node in the DAG as the number of reads consistent with it. By extension, the support of a path through the DAG is defined as the minimum of the support values of each of the nodes in that path.
[0130] Once support for each of a plurality of paths through the DAG has been determined according to a number of reads consistent with a location in that path that is consistent with fewer reads than any other location in that path, then a number of the paths meeting a pre-determined support criteria may be identified as describing relevant haplotypes.
[0131] In certain embodiments, the foregoing steps may include the following specific methodological steps. Let n be the number of paths with support greater than or equal to some constant chosen before the process (perhaps 3% of the number of reads divided by the number of samples from which the reads were drawn). Let k be two times the number of human genomes represented in the set from which the reads were drawn. If n is less than or equal to k, then each of the n paths is a “relevant” haplotype. (Throughout this discussion, “relevant” means “evidentially supported in the sample to such a degree that one can posit its existence in the source of the sample.”) Otherwise, the k best-supported haplotypes are the relevant ones.
5. Systems of the Invention.
[0132] FIG. 10 illustrates a computer system 1001 useful for implementing methodologies described herein. A system of the invention may include any one or any number of the components shown in FIG. 10 . Generally, a system 1001 may include a computer 1033 and a server computer 1009 capable of communication with one another over network 1015 . Additionally, data may optionally be obtained from a database 1005 (e.g., local or remote). In some embodiments, systems include an instrument 1055 for obtaining sequencing data, which may be coupled to a sequencer computer 1051 for initial processing of sequence reads.
[0133] In some embodiments, methods are performed by parallel processing and server 1009 includes a plurality of processors with a parallel architecture, i.e., a distributed network of processors and storage capable of comparing a first sequence DAG to a second sequence DAG. The system comprises a plurality of processors that simultaneously execute a plurality of comparisons between a plurality of reads and the reference sequence construct. While other hybrid configurations are possible, the main memory in a parallel computer is typically either shared between all processing elements in a single address space, or distributed, i.e., each processing element has its own local address space. (Distributed memory refers to the fact that the memory is logically distributed, but often implies that it is physically distributed as well.) Distributed shared memory and memory virtualization combine the two approaches, where the processing element has its own local memory and access to the memory on non-local processors. Accesses to local memory are typically faster than accesses to non-local memory.
[0134] Processor-processor and processor-memory communication can be implemented in hardware in several ways, including via shared (either multiported or multiplexed) memory, a crossbar switch, a shared bus or an interconnect network of a myriad of topologies including star, ring, tree, hypercube, fat hypercube (a hypercube with more than one processor at a node), or n-dimensional mesh.
[0135] Parallel computers based on interconnected networks incorporate routing to enable the passing of messages between nodes that are not directly connected. The medium used for communication between the processors is likely to be hierarchical in large multiprocessor machines. Such resources are commercially available for purchase for dedicated use, or these resources can be accessed via “the cloud,” e.g., Amazon Cloud Computing.
[0136] One approach to parallelizing Smith-Waterman-type alignments is discussed in Altera, 2007, Implementation of the Smith-Waterman algorithm on reconfigurable supercomputing platform, White Paper ver 1.0 (18 pages), incorporated by reference.
[0137] A computer generally includes a processor coupled to a memory and an input-output (I/O) mechanism via a bus. Memory can include RAM or ROM and preferably includes at least one tangible, non-transitory medium storing instructions executable to cause the system to perform functions described herein. As one skilled in the art would recognize as necessary or best-suited for performance of the methods of the invention, systems of the invention include one or more processors (e.g., a central processing unit (CPU), a graphics processing unit (GPU), etc.), computer-readable storage devices (e.g., main memory, static memory, etc.), or combinations thereof which communicate with each other via a bus.
[0138] A processor may be any suitable processor known in the art, such as the processor sold under the trademark XEON E7 by Intel (Santa Clara, Calif.) or the processor sold under the trademark OPTERON 6200 by AMD (Sunnyvale, Calif.).
[0139] Input/output devices according to the invention may include a video display unit (e.g., a liquid crystal display (LCD) or a cathode ray tube (CRT) monitor), an alphanumeric input device (e.g., a keyboard), a cursor control device (e.g., a mouse or trackpad), a disk drive unit, a signal generation device (e.g., a speaker), a touchscreen, an accelerometer, a microphone, a cellular radio frequency antenna, and a network interface device, which can be, for example, a network interface card (NIC), Wi-Fi card, or cellular modem.
INCORPORATION BY REFERENCE
[0140] References and citations to other documents, such as patents, patent applications, patent publications, journals, books, papers, web contents, have been made throughout this disclosure. All such documents are hereby incorporated herein by reference in their entirety for all purposes.
EQUIVALENTS
[0141] Various modifications of the invention and many further embodiments thereof, in addition to those shown and described herein, will become apparent to those skilled in the art from the full contents of this document, including references to the scientific and patent literature cited herein. The subject matter herein contains important information, exemplification and guidance that can be adapted to the practice of this invention in its various embodiments and equivalents thereof. | The invention provides methods for comparing one set of genetic sequences to another without discarding any information within either set. A set of genetic sequences is represented using a directed acyclic graph (DAG) avoiding any unwarranted reduction to a linear data structure. The invention provides a way to align one sequence DAG to another to produce an alignment that can itself be stored as a DAG. DAG-to-DAG alignment is a natural choice wherever a set of genomic information consisting of more than one string needs to be compared to any non-linear reference. For example, a subpopulation DAG could be compared to a population DAG in order to compare the genetic features of that subpopulation to those of the population. | 2 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application Ser. No. 61/036,862, filed Mar. 14, 2008 and entitled “Cam Lock Electrode Clamp,” which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention relates generally to the field of process equipment used in the semiconductor, data storage, flat panel display, as well as allied or other industries. More particularly, the present invention relates to a cam-operated clamp for attaching an electrode or other material to a backing plate within the process equipment.
BACKGROUND
[0003] Semiconductor device geometries (i.e., integrated circuit design rules) have decreased dramatically in size since such devices were first introduced several decades ago. Integrated circuits (ICs) have generally followed “Moore's Law,” which means that the number of devices which will fit on a single integrated circuit chip doubles every two years. Today's IC fabrication facilities are routinely producing 65 nm (0.065 μm) feature size devices, and future fabs soon will be producing devices having even smaller feature sizes.
[0004] Commonly used and critical processes employed in fabs include dry plasma etching, reactive ion etching, and ion milling techniques. These techniques were developed in order to overcome numerous limitations associated with chemical etching of semiconductor wafers. Plasma etching, in particular, allows a vertical etch rate to be made much greater than a corresponding horizontal etch rate so that a resulting aspect ratio of the etched features can be adequately controlled.
[0005] During the plasma etching process, a plasma is formed above the masked surface of the wafer by adding large amounts of energy to a gas at relatively low pressure, resulting in an ionized gas. By adjusting the electrical potential of the substrate to be etched, charged species in the plasma can be directed to impinge substantially normally upon the wafer wherein materials in the unmasked regions of the wafer are removed.
[0006] The etching process can often be made more effective by using gases that are chemically reactive with the material being etched. Reactive ion etching (RIE) combines energetic etching effects of the plasma with a chemical etching effect of the gas. However, many chemically-active agents have been found to cause excessive electrode wear. The worn electrodes need to be quickly and efficiently replaced in order to maintain high process yields within the fab.
[0007] A reactive ion etching system typically consists of an etching chamber with an upper electrode (an anode) and a lower electrode (a cathode) positioned therein. The cathode is negatively biased with respect to the anode and the chamber walls. The wafer to be etched is covered by a suitable mask and placed directly on the cathode (e.g., typically an electrostatic chuck). A chemically reactive gas such as carbon tetrafluoride (CF 4 ), trifluoromethane (CHF 3 ), chlorotrifluoromethane (CCIF 3 ), sulfur hexafluoride (SF 6 ), or mixtures thereof, is combined with oxygen (0 2 ), nitrogen (N 2 ), helium (He), or argon (Ar) and introduced into the etching chamber and maintained at a pressure which is typically in the millitorr range.
[0008] The upper electrode is typically provided with gas apertures which permit the input gas to be uniformly dispersed through the electrode into the chamber. The electric field established between the anode and the cathode dissociates the reactive gas, thus forming a plasma. The surface of the wafer is etched by chemical interaction with the active ions and by momentum transfer of the ions striking unmasked portions of the wafer. The electric field created by the electrodes will attract the ions to the cathode, causing the ions to strike the wafer in a predominantly vertical direction so that the process produces well-defined vertically etched side walls.
[0009] With reference to FIG. 1 , a typical prior art showerhead electrode assembly 100 for a single wafer etcher is used in which a wafer is supported and spaced one to two centimeters below a silicon electrode 101 . An upper surface of the outer edge of the silicon electrode 101 is metallurgically bonded by, for example, silicone or an indium or indium alloy solder to a graphite supporting ring 109 . The silicon electrode 101 is a planar disk having uniform thickness from center to edge thereof. The silicon electrode 101 may also take other forms, such as an annular ring. An outer flange on the graphite supporting ring 109 is clamped by an aluminum clamping ring 113 to an aluminum support member 105 . The aluminum support member 105 has a peripheral water cooling channel 111 . A plasma confinement ring 107 comprised of a Teflon® support ring 107 A and an annular Vespel® insert 107 B surrounds the outer periphery of the silicon electrode 101 .
[0010] The purpose and function of the plasma confinement ring 107 is to increase the electrical resistance between the walls of the reaction chamber and the plasma, thereby confining the plasma more directly between the upper and lower electrodes. The aluminum clamping ring 113 is attached to the aluminum support member 105 by a plurality of circumferentially spaced-apart stainless steel bolts threaded into the aluminum support member 105 . The plasma confinement ring 107 is attached to the aluminum clamping ring 113 by a plurality of circumferentially spaced-apart bolts threaded into the aluminum clamping ring 113 . A radially inwardly-extending flange of the aluminum clamping ring 113 engages the outer flange of the graphite support ring 109 . Thus, no clamping pressure is applied directly against the exposed surface of the silicon electrode 101 .
[0011] Process gas is supplied to the silicon electrode 101 through a central hole 115 in the aluminum support member 105 . The process gas is then dispersed through one or more vertically spaced apart baffle plates 103 and passes through gas dispersion holes (not shown) in the silicon electrode 101 to evenly disperse the process gas into the reaction chamber (i.e., the reaction chamber is immediately below the silicon electrode 101 ).
[0012] In order to provide enhanced heat conduction between the graphite support ring 109 and the aluminum support member 105 , part of the process gas is supplied through a first gas passage orifice 119 to fill a small annular groove in the aluminum support member 105 . In addition, a second gas passage orifice 117 in the plasma confinement ring 107 permits pressure to be monitored in the reaction chamber. To maintain process gas under pressure between the aluminum support member 108 and the graphite support ring 109 , a first O-ring seal 121 is provided between a radially inner surface of the graphite support ring 109 and a radially outer surface of the aluminum support member 105 . A second O-ring seal 123 is provided between an outer part of an upper surface of the graphite support ring 109 and a lower surface of the aluminum support member 105 .
[0013] A difficult and time-consuming prior art process of bonding the silicon electrode 101 to the graphite support ring 109 requires heating the silicon electrode 101 to a bonding temperature which may cause bowing or cracking of the electrode 101 due to the different thermal coefficients of expansion of the silicon electrode 101 and the graphite support ring 109 . Also, contamination of wafers could result from solder particles or vaporized solder contaminants deriving from the joint between the silicon electrode 101 and the graphite support ring 109 or from the ring itself. The problem with such particulates or other contaminants becomes far more pronounced with sub-65 nanometer design rules employed in contemporaneous IC designs.
[0014] In the silicon electrode 101 bonding process, the temperature of the electrode 101 may even become high enough to melt the solder and cause either part or the entire electrode 101 to separate from the graphite support ring 109 . However, even if the silicon electrode 101 becomes only partly separated from the graphite support ring 109 , local variations in electrical and thermal power transmission between the graphite support ring 109 and the silicon electrode 101 could result in a non-uniform plasma density beneath the electrode 10 1 .
[0015] Therefore, what is needed is an efficient means of mounting an electrode to a support or backing ring that is simple, robust, and cost-effective. Also, the mounting means must account for any induced stresses due to thermal coefficient differences between the electrode and the support member.
SUMMARY
[0016] In an exemplary embodiment, a cam lock clamp is disclosed. The cam lock clamp comprises a stud having a body portion, a first end portion, and a second end portion. The first end portion includes a head area having a first diameter larger than a cross-sectional dimension of the body portion; the second end portion includes a second diameter larger than the cross-sectional dimension of the body portion and arranged to support one or more disc springs concentrically about the stud. A socket is arranged to mechanically couple concentrically around the stud and the supported one or more disc springs with the head area of the stud being exposed above an uppermost portion of the socket. The socket is configured to be firmly attached to a consumable material. The cam lock clamp also comprises a camshaft with a substantially cylindrical body with a diameter larger than the first diameter. The camshaft is configured to mount within a bore of a backing plate and further comprises an eccentric cutout area located in a central portion of the cylindrical camshaft body. The camshaft is further configured to engage and lock the head area of the stud when the consumable material and the backing plate are proximate to one another.
[0017] In another exemplary embodiment, a cam lock clamp is disclosed. The cam lock clamp comprises a stud having a body portion, a first end portion, and a second end portion. The first end portion includes a head area having a first diameter larger than a cross-sectional dimension of the body portion; the second end portion includes a second diameter larger than the cross-sectional dimension of the body portion and arranged to support one or more disc springs concentrically about the stud. A socket is arranged to mechanically couple concentrically around the stud and the supported one or more disc springs with the head area of the stud being exposed above an uppermost portion of the socket. The socket is configured to be firmly attached to a backing plate. The cam lock clamp also comprises a camshaft with a substantially cylindrical body with a diameter larger than the first diameter. The camshaft is configured to mount within a bore of a consumable material and further comprises an eccentric cutout area located in a central portion of the cylindrical camshaft body. The camshaft is further configured to engage and lock the head area of the stud when the backing plate and the consumable material are proximate to one another.
[0018] In another exemplary embodiment, a cam lock clamp for use in a semiconductor process tool is disclosed. The cam lock clamp comprises a stud having a substantially cylindrical body portion, a first end portion, and a second end portion. The first end portion comprises a head area having a first diameter larger than a diameter of the substantially cylindrical stud body portion. The second end has a second diameter larger than the diameter of the cylindrical stud body portion and is arranged to support a plurality of disc springs concentrically about the stud. A socket is arranged to mechanically couple concentrically around the stud and the supported plurality of disc springs with the head area of the stud being exposed above an uppermost portion of the socket. The socket is configured to be firmly attached to an electrode located within the semiconductor process tool. A camshaft having a substantially cylindrical body with a diameter larger than the first diameter is configured to mount within a bore of a backing plate located with the semiconductor process tool and further comprising an eccentric cutout area located in a central portion of the cylindrical camshaft body. The camshaft is further configured to engage and lock the head area of the stud when the electrode material and the backing plate are proximate to one another. The cam lock clamp further comprises a pair of camshaft bearings having an inside diameter and an outside diameter. The inside diameter is sized such that the pair of camshaft bearings are mountable over opposite ends of the camshaft and the outside diameter is sized to be larger than the diameter of the camshaft.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The appended drawings illustrate exemplary embodiments of the present invention and must not be considered as limiting its scope.
[0020] FIG. 1 is a cross-sectional view of a plasma showerhead of the prior art.
[0021] FIG. 2A is a three-dimensional representation of an exemplary cam lock electrode clamp in accordance with the present invention.
[0022] FIG. 2B is a cross-sectional view of the exemplary cam lock electrode clamp of FIG. 2A .
[0023] FIG. 3 shows side-elevation and assembly drawings of an exemplary stud used in the cam lock clamp of FIGS. 2A and 2B .
[0024] FIG. 4A shows side-elevation and assembly drawings of an exemplary cam shaft used in the cam lock clamp of FIGS. 2A and 2B .
[0025] FIG. 4B shows a cross-sectional view of an exemplary cutter-path edge of a portion of the cam shaft of FIG. 4A .
DETAILED DESCRIPTION
[0026] With reference to FIG. 2A , a three-dimensional view of an exemplary cam lock electrode clamp of the present invention includes portions of an electrode 201 and a backing plate 203 to exemplify to a skilled artisan how the cam lock electrode clamp functions. The electrode clamp is capable of quickly, cleanly, and accurately attaching a consumable electrode 201 to a backing plate in a variety of fab-related tools, such as a dielectric etch chamber (not shown). The electrode 201 may be comprised of a variety of materials including, for example, silicon (Si), silicon carbide (SiC), or polysilicon (α-Si). The backing plate is frequently comprised of aluminum although other materials are known in the art.
[0027] Comprising portions of the electrode clamp, a stud 205 is mounted into a socket 213 . The stud may be surrounded by a disc spring stack 215 , such, for example, stainless steel Belleville washers. The stud 205 and disc spring stack 215 may then be press-fit or otherwise fastened into the socket 213 through the use of adhesives or mechanical fasteners. The stud 205 and the disc spring stack 215 are arranged into the socket 213 such that a limited amount of lateral movement is possible between the electrode 201 and the backing plate 203 . Limiting the amount of lateral movement allows for a tight fit between the electrode 201 and the backing plate 203 , thus ensuring good thermal contact, while still providing some movement to account for differences in thermal expansion between the two parts. Additional details on the limited lateral movement feature are discussed in more detail, below.
[0028] In a specific exemplary embodiment, the socket 213 is fabricated from bearing-grade Torlon®. Alternatively, the socket 213 may be fabricated from other materials possessing certain mechanical characteristics such as good strength and impact resistance, creep resistance, dimensional stability, radiation resistance, and chemical resistance may be readily employed. Various materials such as polyamides, polyimides, acetals, and ultra-high molecular weight polyethylene materials may all be suitable. High temperature-specific plastics and other related materials are not required for forming the socket 213 as 230° C. is a typical maximum temperature encountered in applications such as etch chambers. Generally, a typical operating temperature is closer to 130° C.
[0029] Other portions of the electrode clamp are comprised of a camshaft 207 surrounded at each end by a pair of camshaft bearings 209 . The camshaft 207 and camshaft bearing assembly is mounted into a backing plate bore 211 machined into the backing plate 203 . In a typical application for an etch chamber (not shown) designed for 300 mm semiconductor wafers, eight or more of the electrode clamps may be spaced around the periphery of the electrode 201 /backing plate 203 combination.
[0030] The camshaft bearings 209 may be machined from a variety of materials including Torlon®, Vespel®, Celcon®, Delrin®, Teflon®, Arlon®, or other materials such as fluoropolymers, aceta Is, polyamides, polyimides, polytetrafluoroethylenes, and polyetheretherketones (PEEK) having a low coefficient of friction and low particle shedding. The stud 205 and camshaft 207 may be machined from stainless steel (e.g., 316, 316L, 17-7, etc.) or any other material providing good strength and corrosion resistance.
[0031] Referring now to FIG. 2B , a cross-sectional view of the electrode cam clamp further exemplifies how the cam clamp operates by pulling the electrode 201 in close proximity to the backing plate 203 . The stud 205 /disc spring stack 215 /socket 213 assembly is mounted into the electrode 201 . As shown, the assembly may be screwed, by means of external threads on the socket 213 into a threaded pocket in the electrode 201 . However, a skilled artisan will recognize that the socket may be mounted by adhesives or other types of mechanical fasteners as well.
[0032] In FIG. 3 , an elevation and assembly view 300 of the stud 205 , disc spring stack 215 , and socket 213 provides additional detail into an exemplary design of the cam lock electrode clamp. In a specific exemplary embodiment, a stud/disc spring assembly 301 is press fit into the socket 213 . The socket 213 has an external thread and a hexagonal top member (or any other shape such as, for example, polygonal, Torx®, Robertson, etc.) allowing for easy insertion into the electrode 201 (see FIGS. 2A and 2B ) with light torque (e.g., in a specific exemplary embodiment, about 20 inch-pounds). As indicated above, the socket 213 may be machined from various types of plastics. Using plastics minimizes particle generation and allows for a gall-free installation of the socket 213 into a mating pocket on the electrode 201 .
[0033] The stud/socket assembly 303 illustrates an inside diameter in an upper portion of the socket 213 being larger than an outside diameter of a mid-section portion of the stud 205 . The difference in diameters between the two portions allows for the limited lateral movement in the assembled electrode clamp as discussed above. The stud/disc spring assembly 301 is maintained in rigid contact with the socket 213 at a base portion of the socket 213 while the difference in diameters allows for some lateral movement. (See also, FIG. 2B .)
[0034] With reference to FIG. 4A , an exploded view 400 of the camshaft 207 and camshaft bearings 209 also indicates a keying pin 401 . The end of the camshaft 207 having the keying pin 401 is first inserted into the backing plate bore 211 (see FIG. 2B ). A half-moon shaped slot (not shown) at a far end of the backing plate bore 211 provide proper alignment of the camshaft 207 into the backing plate bore 211 . The half-moon shaped slot limits rotational travel of the camshaft 207 thus preventing damage to the stud 205 . A side-elevation view 420 of the camshaft 207 clearly indicates a possible placement of a hex opening 403 on one end of the camshaft 207 and the keying pin 401 on the opposite end.
[0035] For example, with continued reference to FIGS. 4A and 2B , the electrode cam clamp is assembled by inserting the camshaft 207 into the backing plate bore 211 . The keying pin 401 limits rotational travel of the camshaft 207 in the backing plate bore 211 by interfacing with one of the pair of small mating holes. The camshaft may first be turned in one direction though use of the hex opening 403 , for example, counter-clockwise, to allow entry of the stud 205 into the camshaft 207 , and then turned clockwise to fully engage and lock the stud 205 . The clamp force required to hold the electrode 201 to the backing plate 203 is supplied by compressing the disc spring stack 215 beyond their free stack height. The camshaft 207 has an internal eccentric internal cutout which engages the head of the shaft 205 . As the disc spring stack 215 compresses, the clamp force is transmitted from individual springs in the disc spring stack 215 to the socket 213 and through the electrode 201 to the backing plate 203 .
[0036] In an exemplary mode of operation, once the camshaft bearings are attached to the camshaft 207 and inserted into the backing plate bore 211 , the camshaft 207 is rotated counterclockwise to its full rotational travel. The stud/socket assembly 303 ( FIG. 3 ) is then lightly torqued into the electrode 201 . The head of the stud 205 is then inserted into the through hole below the backing plate bore 211 . The electrode 201 is held against the backing plate 203 and the camshaft 207 is rotated clockwise until either the keying pin 401 travels until it contacts the end of the half-moon shaped slot (not shown) or an audible click is heard (discussed in detail, below). The exemplary mode of operation may simply be reversed to dismount the electrode 201 from the backing plate 203 .
[0037] With reference to FIG. 4B , a sectional view A-A of the side-elevation view 420 of the camshaft 207 of FIG. 4A indicates a cutter path edge 440 by which the head of the stud 205 is fully secured. In a specific exemplary embodiment, the two radii R 1 and R 2 are chosen such that the head of the stud 205 makes the audible clicking noise described above to indicate when the stud 205 is fully secured.
[0038] The present invention is described above with reference to specific embodiments thereof. It will, however, be evident to a skilled artisan that various modifications and changes can be made thereto without departing from the broader spirit and scope of the present invention as set forth in the appended claims. For example, particular embodiments describe a number of material types and locations of various elements of the electrode cam clamp. A skilled artisan will recognize that these materials and particular elements are flexible and are shown herein for exemplary purposes only in order to fully illustrate the novel nature of the clamp. Additionally, a skilled artisan will further recognize that various mounting configurations are possible such as reversing a location of the clamp by mounting the stud assembly into the backing plate and the camshaft into the backing plate. Also, the clamp may be used in a variety of different materials on a variety of, for example, process, metrology, and analytical tools within a fab. Moreover, the term semiconductor should be construed throughout to include data storage, flat panel display, as well as allied or other industries. These and various other embodiments are all within a scope of the present invention. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. | A cam lock clamp comprises a stud having a substantially cylindrical body with a first end including a head area and a second end arranged to support one or more disc springs concentrically about the stud. A socket is arranged to mechanically couple concentrically around the stud with the head area of the stud being exposed above an uppermost portion of the socket. The socket is configured to be firmly attached to a consumable material. A camshaft has a substantially cylindrical body and is configured to mount within a bore of a backing plate. The camshaft further comprises an eccentric cutout area located in a central portion of the camshaft body. The camshaft is configured to engage and lock the head area of the stud when the consumable material and the backing plate are proximate to one another. | 7 |
TECHNICAL FIELD
This invention relates to methods and apparatus for providing secure dialable access to a target computer.
PROBLEM
In recent years there has been an increasing demand for dial-up access to target computers such as centralized host computers or centralized data bases. One example of this kind of application is one wherein a manufacturer maintains a data base for controlling orders for spare parts which is accessible from a large number of franchise dealers. A problem with such dial-up data bases is that they must be secure from the intrusion of outsiders with malicious intent who might mutilate the data in a data base, for example, by placing a very large false order to a particular part thereby making the spare part unavailable for other dealers. There have been instances in which a malicious user completely mutilated data files requiring a very large effort to restore them to a working basis.
In some cases, these target computers are accessed by 800 numbers which means that the bill for calls is accepted by the owner of the target computer and not the callers. In such cases, malicious unauthorized users who are trying to access the data base have used personal computers programmed to place large numbers of calls to tray different permutations of possible logins and passwords in an attempt to access the target computer; under these circumstances the owner of the target computer has sometimes been faced with very large non-revenue producing telephone bills to pay for the efforts of those who are trying to gain unauthorized access to the data base.
The most common way of protecting these target computers from unauthorized access is to screen calls with a device that contains a list of telephone numbers of agents authorized to access the target computer. When a call is received from one of these agents, the device calls that agent back using one of these previously recorded telephone numbers. This procedure is inconvenient for the agent because the agent must call, login to the device, and then disconnect and wait for the return of the call. The procedure is also expensive because it requires special equipment for dialing the new connection, and is limited because it is difficult economically to accommodate a large number of users with presently available dial back equipment. The convenience factor is particularly important since the owner of the target computer is frequently dependent upon the business brought by the agents or franchises. An arrangement using an adjunct processor for processing logins and for automatically initiating a call back for connecting the target computer to the user is described in a co-pending application by S. Barron et al., Ser. No. 205,054, assigned to the assignee of this invention, now U.S. Pat. No. 4,876,717.
An alternate approach to protecting these target computers against intrusion from unauthorized users is to provide good login procedures. Such procedures have not always been tamperproof in the past and further, in many cases the users of the target computer are not sophisticated computer users and therefore the login procedures must necessarily be straightforward.
Another approach is to provide a caller with a special device which performs a calculation or carries out some function that is difficult for an unauthorized caller to copy. One example of this is the Secure Net Key™ device used with the Defender II™ system provided by Digital Pathways, Incorporated. Each user is provided with a special calculator that includes a personalized algorithm. When the user calls into the system, the system generates a random number and subjects that random number to the inverse of the calculation associated with the caller. The caller then receives the results of this calculation, performs the calculation using his own unit, and returns the result of this calculation back to the system. If the result matches the random number originally generated in the data base system, the caller is authorized. This arrangement, while being relatively tamperproof, is very difficult for inexperienced agents to use, and requires the use of an expensive device which, if lost to an unauthorized user, leaves the target computer defenseless.
Arrangements for intercepting calls from certain telephone numbers, or for only letting calls from certain telephone numbers complete are disclosed in D. Sheinbein, U.S. Pat. No. 4,277,649. The telephone numbers of the callers are identified by automatic number identification (ANI). These arrangements are completely controlled from a common carrier switching office, thus limiting the ability of an administrator of a target computer to customize the process of accepting or rejecting calls in accordance with the special needs of a particular business.
A problem of the prior art therefore is that arrangements for ensuring that only authorized users can receive direct dial-up access to a target computer are either inconvenient, inflexible, or expensive.
SOLUTION
The above problem is solved and an advance is made over the prior art in accordance with a new method and apparatus wherein a public switched network provides the number of the caller as identified, illustratively, by automatic number identification (ANI), to an adjunct processor for a target computer, the caller's number is then compared with a list of authorized numbers and the caller is connected to the target computer only if the number matches one of these authorized numbers.
In order to make a dial up access system secure, it is important that the identification of the calling location be secure. ANI is one secure method of identifying a caller since it is not supplied by the caller, but is determined within the public switched network, and is therefore highly tamperproof. Caller supplied caller identification is, of course, much less secure and would not be appropriate for this type of application. However, any secure identification of the caller, that is, an identification which is not under the control of the caller, is satisfactory for the purposes of this invention. While the most common callers are persons operating a terminal, the caller may also be a computer or terminal programmed to call automatically.
In one specific implementation, an integrated services digital network (ISDN) primary rate interface (PRI) is used to connect a switching system of a public switched network to a private branch exchange (PBX) connected to ports of a target computer. The PBX has an adjunct processor for comparing the caller's number as identified by automatic number identification with lists of prestored numbers. If the number matches one of these lists of prestored numbers, the call is routed by the PBX to one of a set of ports of the target computer. Routing by list enables legitimate users to be directed to the ports associated with the particular application they need to access or with the particular data networking hardware they use.
In accordance with one aspect of the invention, the adjunct processor also maintains a separate list of numbers associated with callers that are to be rejected. This number list is built up as a result of having had a large number of calls from a particular number, none of which calls ever resulted in a successful login. The list is administratable by a security administrator. If calls come from one of these numbers, the call is simply not accepted. In accordance with one aspect of this feature, answer supervision is not returned for this call, so that if an unauthorized call is made to an 800 number, the owner of the target computer will not in general be charged for the call.
In accordance with another aspect of this invention arrangements are available to trap malicious unauthorized users by accepting calls from these users, identified by a special list of numbers, in a specialized way. The calls are routed to a processor containing special programs to trap such callers. Records of such calls can be useful in subsequent prosecution of such malicious callers.
In accordance with another aspect of the invention, for calls which are from numbers that are not in the accept list and not in the reject or trap lists, further attempts are made to allow such calls to login using special login procedures and under some circumstances to help the caller reach an operator for assistance. These calls are subjected to special login procedures. Such calls might come, for example, from traveling agents who must of necessity make calls from unplanned telephone stations lacking telephone numbers on a previously defined list. Such special login procedures would include an initial simple special login which permits the traveling agent to identify himself or herself. This login is followed by prior art security procedures for verifying the identity of the caller, such as a request for the caller's mother's maiden name, or a machine generated password, or a zero proofing algorithm procedure similar to the Secure Net Key device described above. Illustratively, for calls which fail the special login procedures, a display providing the telephone number of an operator accompanied by an audio announcement to the same effect is returned to the caller so that new users can be helped. Further, whenever there is an indication of many attempts to access the system from the same caller, this can be brought to the attention of a system administrator for appropriate action. The appropriate action in many cases will be to call a new user who may be having initial problems accessing the system. In other cases, the system administrator will add the caller to the disconnect list or the trap list.
In accordance with another aspect of the invention, arrangements are provided for processing calls when no user identification is received. This situation may occur if the user is calling from a location served by a switching system that does not forward an ANI number to the public switched network. Such users can then be processed using special login procedures. Based on the caller'simple special login, the caller is dialed back. If the caller is a traveling user, the caller is given extended login treatment as for callers with unrecognized caller identification.
In accordance with another aspect of the invention, all calls to the security system are recorded. These records allow legitimate users to be billed for the calls and allow illegitimate users to be detected and prosecuted. Provisions are included for long-term archieving of these records.
In accordance with another aspect of the invention, all calls to the security system are counted by ANI number. When the count exceeds a threshold within a given amount of time, the security administrator is notified. The security administrator will place the ANI number on the disconnect list or the trap list.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a block diagram of the operation of the invention showing processors for ascertaining caller authorization;
FIGS. 2 and 3 are flow diagrams of programs executed by these processors; and
FIG. 4 is a flow diagram of a program executed by a processor for trapping unauthorized callers.
DETAILED DESCRIPTION
FIG. 1 is a block diagram illustrating the operation of the invention. A caller 101 is connected through a local exchange carrier 103 to a toll network 105. The local exchange carrier provides the toll network 105 with the billing number of the caller as identified through automatic number identification via a message 107 or via a series of digits transmitted though a signaling system such as the multifrequency signaling system. The toll network is connected to the PBX 121 which accesses the target computer 150 over an access facility 108 through an Integrated Services DIgital Network (ISDN) primary rate interface (PRI) connection 109. The D-channel of this primary rate interface carries a setup message 111 including the automatic number identification number 113 to the PBX 121. PBX 121 passes this automatic number identification number to adjunst processor 131, a processor that, in common with other processors 160, 170 and 174, is controlled by a program, in this case program 132. The adjunct processor 131 has as associated data base 133 which stores a list 134 of numbers 135 authorized to access the target computer, and, optionally, an indication 136 of the type of user in case different types of users are connected to different ports of the target computer. Effectively, the type indicator is a way of permitting a plurality of sublists, one for each type to be combined in one list. In addition, the data base also stores a list 137 of numbers to be rejected outright and a list 139 of numbers whose callers are to be routed to a trap processor. The adjunct processor also maintains records 141 by the ANI number of the calls. These records include the ANI number 143, the optional type of service requested 145, and a count 147 of the number of calls. These records are used to provide immediate notification of break-in attempts or legitimate user problems. They are also stored for later analysis.
The data base also contains a log 144 for maintaining records of all calls. The log contains the automatic number identification number 146, the disposition of the call 148 (whether the call was accepted or rejected, and which of the processors the call was routed to) and the time of the call 149. This log is periodically archived and, where appropriate, printed for the use of the system administrator. The system administrator has access to the adjunct and auxiliary processors at terminal 154, connected via PBX 109 to these processors.
If the call is accepted, it is routed via modem 152 to a port on target computer 150. More generally, if the target has groups of ports for different users, the type of user is identified from the type indication 136 of table 135 associated with the billing number, and the caller is connected to a port for that type of user. If the call is rejected, it is not routed further from the PBX and the caller never receives answer supervision; consequently even if this is a call to an 800 number, the owner of the target is generally not charged for the call. If the call is to be trapped, the call is routed via PBX 121 to trap processor 174 via modem 176. If the caller's number is not on either the authorized reject or trap list, then call is routed via modem 162 to auxiliary processor 160 for further verification as described below. If the result of the further verification is that the caller is authorized to access the target computer then the call is transferred via PBX 121 to target computer 150. If the call is rejected in the auxiliary processor then the call is rerouted from PBX 121 via modem 172 to help processor 170. The help processor will then generate a help screen for transmission back to the caller so that the caller receives a telephone number which may be called for assistance. In addition, the help processor may cause an audible help message to be transmitted back to the caller.
Some customers may prefer to reject any call which is not on the authorized list 135 of the adjunct processor. Such calls would then be rejected without being routed to the auxiliary or trap processor.
While in this preferred embodiment separate processors are used for the roles of adjunct processor, trap processor, auxiliary processor, help processor and target computer, several of the roles may e given to one processor or computer.
If the auxiliary processor recognizes a situation wherein no ANI number has been provided but the caller identifies himself as a caller from a fixed location whose serving office does not provide automatic number identification, then the auxiliary processor causes a dial back connection to be established to the caller at a number stored in tables of the auxiliary processor. The dial back connection is then established from the target computer via the PBX to the caller.
FIG. 2 is a flow diagram of actions performed by the adjunct processor 131. The adjunct processor receives a call setup message from PBX 121 (action block 201) and checks whether the setup message contains an ANI number (test 203). If not, this is an indication that the call came from a caller connected to a local exchange carrier that did not provide for the forwarding of an ANI number. If that is the case, then the call is routed to the auxiliary processor for further login procedures (action block 205). In addition, the count of attempts from locations not served by local exchange carriers that forward the ANI number is incremented and the call is logged.
If the setup message does contain an ANI number, a check is made in the adjunct processor whether this is an authorized ANI number (test 207). If so, then the type of port for that user is used to select a port of the target for handling calls from that type of user and the call is routed to that port of the target (action block 209), the call is logged and the count of calls from that ANI number is incremented.
If the ANI number is not an authorized ANI number, then the ANI number is checked to see if it is in the list of ANI numbers to be rejected (test 211). If so, then the call is rejected (action block 213), a record of the call is made in the log, and the count of calls from that ANI number is incremented. This rejection, as previously indicated, is made without returning answer supervision to the caller so that there is generally no charge for this call. The count of the number of calls from this ANI number is compared to a threshold (test 221) and if it exceeds this threshold, preset, for example, by a security administrator, an optional alarm is given (action block 223).
If the ANI number is not on the list of rejected ANI numbers, then a further test is made to see whether the ANI number is on the list of ANI numbers to be trapped (test 215). If so, then the call is routed to the trap processor (action block 217), the call is logged, and the count of calls from that ANI number is incremented. An optional alarm is also given (action block 225).
If the ANI number is also not on the list of ANI numbers to be trapped then the call is routed to the auxiliary processor for extended login procedures and the call is logged and the count for calls from that ANI number is incremented (action block 219).
FIG. 3 is a flow diagram of actions performed in the auxiliary processor. The auxiliary processor receives calls which either had no ANI number (negative result of test 203), or whose ANI number was not on any of the lists of authorized rejected or trapped ANI numbers. The auxiliary processor requests a special login (action block 301). This special login may simply represent the name of the agent. The purpose is merely to establish on a preliminary basis whether the call is from a known traveling agent or other agent known to the system though not identified by an ANI number. Test 303 checks whether the special login was accepted, i.e., that that particular login identification is known to the system. The test is performed by searching the data base 161 of auxiliary processor 160 to find an identification such as 164 in table 163 or 167 in table 166. If the result of test 303 is negative, i.e., that the special login is not known to the system, then a connection is set up to a help processor (action block 305). Such a help processor would, for example, send an audible message and a video screen identifying a number to be called to receive additional instructions. This leg of the program might represent, for example, newly attached agents or agents for whom records had not yet been made in the adjunct processor.
If the special login is accepted (positive result of test 303), then test 307 checks whether that caller has an identification listed in table 163 can be called back at a prerecorded number 165 corresponding to an identification 164. If so, dial back procedures will be used to establish the call. First, the prerecorded directory number of the caller is found (action block 309) and a connection is set up from the target to the caller using dial back procedures (action block 311). This portion of the program is used for calling callers who are connected to local exchange carriers that do not forward an ANI number or from callers calling from within a PBX whose specific ANI number is not sufficient to reliably establish the identity of the specific calling location. Dialback is a reliable method of authenticating communications and is equivalent to the degree of security attained from receiving an ANI number that is on the list of authorized ANI numbers.
If the result of test 307 is negative, that is that the caller cannot be called back at a prerecorded number because, for example, the caller is a traveling agent calling from a hotel or a site of the agent's customer, then a more extended login procedure (action block 313) is used to verify that this is, in fact, a traveling agent and not an unauthorized user.
In this case, the caller identification is in table 166 which contains data such as a password 168 corresponding to identification 167 for verifying the identity of the caller. Examples of this extended login procedure are to request one of a number of specialized passwords associated with the agent as identified by the special login; these special passwords might be, for example, a social security number, mother's maiden name, child's birthday etc. Other extended login procedures might be procedures used in connection with a zero proofing algorithm as previous described in the problem section of this application, or recognition of a signal from a "smart card". Test 315 checks whether the extended login procedure was passed. If so, then the call is connected to the target (action block 317); otherwise a connection is set up to the help processor (action block 319).
FIG. 4 is a flow diagram of actions performed in the trap processor. The objective of these actions is to attempt to capture information which identifies the caller as performing unauthorized acts such as trying a large number of passwords on a random basis in an attempt to be logged onto the target computer. The trap processor, therefore, first issues a request to the caller to submit his login and password (action block 401). The trap processor then records the login and password along with the ANI number associated with the trapped call and increments the count of password attempts (action block 403). Test 405 checks whether this count exceeds some threshold. If not, then action block 401 is performed again and another attempted password is recorded. If he count exceeds the threshold, then the call is disconnected (action block 407).
It is to be understood that the above description is only of one preferred embodiment of the invention. Numerous other arrangements may be devised by one skilled in the art without departing from the spirit and scope of the invention. the invention is thus limited only as defined in the accompanying claims. | This invention relates to a method and apparatus for making it difficult for unauthorized callers to access a target computer such as a data base for providing data to and accepting orders from agents. The caller is identified by an arrangement that is relatively secure from tampering. The caller's telephone number is identified by Automatic Number Identification (ANI) and forwarded to an adjunct processor associated with the target computer. The ANI number is compared with a stored list of authorized ANI numbers and if there is a match, the caller is connected to the target computer. The arrangement also provides other facilities including automatic rejection of calls from a second list of ANI numbers, trapping of calls from a third list of ANI numbers and facilities for permitting authorized agents calling from unauthorized numbers to access the target computer. Advantageously, an arrangement, ANI, which is highly resistant to tampering is used for identifying the caller, thus making it very difficult for unauthorized callers to get access to the target computer. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part application claiming priority to non-provisional patent application Ser. No. 13/910,571 filed on Jun. 5, 2013, which in turn claims the benefit to Provisional Application No. 61/721,578 filed on Nov. 2, 2012.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates in general to a tablet holder. More particularly, the holder of the present invention is particularly adapted for use with a stroller, carriage or other mobile apparatus.
[0004] 2. Description of Related Art
[0005] There are a variety of different electronic tablets and the like that may be used by people of all ages. This includes instructional computers or tablets for young children. These typically are used in a stationary manner and for educational purposes.
[0006] One of the advantages of using such electronic tablets is its mobility. Electronic tablets are built to be light and easily accessible for using them while traveling. Electronic tablets can provide an entertaining or educational use for children when parents are traveling with them. Such use of electronic tablets can be very helpful when parents need their children to be occupied while attending to other matters. However, using electronic tablets while traveling increases the chance of damaging them which commonly occurs due to unforeseen accidents. When electronic tablets are operated by children while traveling, the chance of damaging them is even higher.
[0007] While there are many holsters for electronic tablets exist to protect the electronic tablets from being damaged in case of an accidental drop or the like, such holsters do not provide a stable platform to hold the electronic tablets in place while a child interacts with them.
[0008] Therefore, a need exists for a tablet holder that can be mounted to a stroller to prevent damages that may occur to electronic tablets when a child operates them while in motion. A need also exists for a tablet holder that can be easily adjustable while providing a stable platform.
SUMMARY OF THE INVENTION
[0009] The subject matter of this application may involve, in some cases, interrelated products, alternative solutions to a particular problem, and/or a plurality of different uses of a single system or article.
[0010] An object of the present invention is to provide such a tablet associated with a stroller, carriage or other mobile apparatus.
[0011] In accordance with the present invention, there is provided a detachable tablet holder that may be removably attached to a stroller, carriage or the like mobile apparatus and which is provided with a number of different adjustments. In this way, a viewing screen of the tablet can be disposed at a convenient location for viewing by the child, particularly while the child is seated within the stroller. When not in use, the tablet holder may be removed from the stroller in a relatively simple manner leaving a portion of the device attached to the stroller and pivotal on either side of the seat of the stroller. The tablet holder may be pivoted between a stowed or rest position and a usable position.
[0012] In one aspect, a detachable tablet holder for a stroller is provided. The detachable tablet holder may comprise a support frame, a plate member, a plurality of upright legs, a platform, and a plurality of support legs. The support frame may be configured to receive the tablet and hold it within the support frame. A locking lever is formed at a back of the support frame placing the support frame in a fixed position when the locking lever is engaged.
[0013] A plate member may be pivotally mounted at the back of the support frame where a securing knob may be placed to tighten the support frame and the plate member in place. A plurality of upright legs may be pivotally attached at a bottom of the plate member. The plurality of upright legs may share a pivot axis extending perpendicular to each of the plurality of upright legs. Such pivot connections among the support frame, the plate member, and the plurality of upright legs allow the tablet therein to be adjustable.
[0014] A platform may provide a flat surface where the plurality of uprights legs may be affixed. The platform may have a plurality of support legs extending downwardly therefrom. Each of the plurality of support legs may be extendable and/or retractable along their length, allowing height adjustment of the platform. Finally, the plurality of support legs may be pivotally attached to the stroller.
[0015] In another aspect, a stroller receiving the detachable tablet holder is provided. The stroller may comprise a handle at a top of the holder enabling it to be maneuvered. A plurality of rails may extend at an angle towards a bottom of the stroller where the plurality of support legs may be pivotally attached. The stroller may comprise a seated area where a child may be placed. The detachable tablet holder may be adjustable to a convenient location for viewing by the child placed in the seated area.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] It should be understood that the drawings are provided for the purpose of illustration only and are not intended to define the limits of the disclosure. In the drawings depicting the present invention, all dimensions are to scale. The foregoing and other objects and advantages of the embodiments described herein will become apparent with reference to the following detailed description when taken in conjunction with the accompanying drawings in which:
[0017] FIG. 1 is a perspective view of the tablet display holder as mounted on a children's stroller;
[0018] FIG. 2 is a fragmentary view illustrating a portion of the holder and the associated tablet display;
[0019] FIG. 3 is a fragmentary view of a portion of the holder;
[0020] FIG. 4 is a fragmentary perspective view illustrating one of the adjustment features of the apparatus of the present invention;
[0021] FIG. 5 is a fragmentary exploded view illustrating the manner in which the apparatus may be separated and removed;
[0022] FIG. 6 is a perspective view showing further details of the portion of the apparatus that remains attached to the stroller but that is pivotal relative to the stroller;
[0023] FIG. 7 illustrates the stroller attached portion of the support apparatus in a stowed position;
[0024] FIG. 8 is a fragmentary view of a portion of another embodiment of the holder;
[0025] FIG. 9 is a perspective of an embodiment of the tablet computer holder configured to attach to various devices; and
[0026] FIG. 10 is a fragmentary view of a portion of another embodiment of the holder.
[0027] FIG. 11 is a fragmentary view of a portion of another embodiment of the holder.
DETAILED DESCRIPTION
[0028] Reference is now made to the perspective view of FIG. 1 that illustrates, what may be considered a conventional stroller at 10 . The stroller 10 has a seated area. In FIG. 1 the child is illustrated in the seated area at 12 . The stroller typically also includes a support wheels 14 and a handle 16 . As a variety of different types of strollers may be used with the apparatus of the present invention, the construction of the stroller itself is not discussed herein in any great detail. The stroller may be one that does not fold up or it may be a stroller of the folding-up type. FIG. 1 also shows opposite side rails 18 that extend from the handle 16 to the bottom of the stroller 10 . FIGS. 6 and 7 illustrate a portion of the apparatus of the present invention attached at the very base of the support rails 18 .
[0029] The tablet contemplated herein may include, but is not limited to mobile computers, tablet computers, laptops, handheld computers, smart phones, electronic readers, and similar display device.
[0030] FIG. 1 also illustrates the novel apparatus of the present invention at 20 which supports a tablet 22 in proper viewing position to a child. This may also enable the child to interact with the tablet 22 depending upon the particular tablet construction.
[0031] In FIG. 1 a detachable tablet holder 20 may be considered as comprised of support legs 24 that is pivotally attached at the base of the rails 18 , on the left and right of the stroller, and a removable portion 26 that is for the main support of the tablet 22 .
[0032] Reference is now made to further details of the detachable tablet holder 20 depicted in FIGS. 2-7 . FIG. 2 is a fragmentary view illustrating a portion of the holder and the associated tablet display.
[0033] In the embodiments shown, the tablet holder device is shown connected to a stroller, but it should be understood that it may be configured to not only attach to a stroller, but can also attach to any other device such as a wheelchair, a standard chair, a table, stool, desk, and the like.
[0034] Portions of the platform 28 are depicted in FIGS. 2-5 . FIGS. 4 and 5 , in particular, depict the end of the platform 28 and the connector 30 having an externally threaded base 31 (see FIG. 5 ). The connector 30 forms an essentially right angle joint connected directly to the platform 28 . FIG. 5 also illustrates a top end of the support legs 24 having an internally threaded collar 32 that is free to rotate and removably mate with a threaded section 31 of the connector 30 . The height of the support legs 24 may also be adjusted by means of a locking ring 34 that can be rotated in the direction of arrow 35 . In this regard, refer to FIG. 4 and the arrows 35 . By rotating the ring 34 in one direction or the other, the post 36 , a portion of the support legs 24 , may be moved up or down for adjusting the overall height of the support legs 24 . This height adjustment is illustrated in FIG. 4 by the arrows 37 . When the locking ring 34 is rotated in one particular direction, it can lock the post 36 in the particular desired height position.
[0035] With further reference to FIGS. 2 and 3 , the platform 28 may be affixed at the bottom of upright legs 52 by a mounting member. The mounting member may connect the upright legs 52 and the platform 28 . In one embodiment, the mounting member may comprise a suction cup 70 . In this embodiment, a frame 40 may comprise of three side pieces 42 fixed to the platform 28 , and a pivotal piece 44 . The frame 40 is for retaining a base of the suction cup 50 that supports the upright legs 52 . As shown in FIG. 2 , a second securing knob 54 may be provided at a top of the upright legs 52 . The second securing knob 54 can be tightened and loosened to allow pivoting of the plate member 56 about a one pivot axis 57 .
[0036] Turning now to FIG. 2 , a top of the plate member 56 further comprises a securing knob 60 that allows for a manipulation and adjustment of the tablet 22 in the direction of double headed arrow 62 . The securing knob 60 may be placed at a pivot point between the support frame 64 and the plate member 56 . The plate member 56 connects to a support frame 64 . The support frame 64 , as depicted in FIG. 2 , may be slid in the direction of arrow 65 so that the opening between the opposed sides of the support frame 64 can be changed to accommodate tablets of different length. The support frame 64 may also be provided with a locking lever 66 for locking a one side end 67 of the support frame 64 in a proper position for securely holding the tablet 22 in place.
[0037] FIG. 3 illustrates the pivotal piece 44 swung to an open position. This enables the base of the suction cup 50 of the detachable tablet holder 20 to be inserted into the frame 40 . To secure the base of the suction cup 50 in place, there may be provided a suction cup 70 that can be operated by means of the lock 72 to force, by a suction action, the suction cup 70 against a flat base piece 74 . The pivotal piece 44 may be opened in the direction of arrow 75 and may be locked to one of the side pieces 42 by means of the locking pin 76 .
[0038] In one embodiment, an aperture may be formed on one of the side pieces 42 . The aperture may be placed to receive the locking pin 76 , thereby securing the pivotal piece 44 from opening when received. In a further embodiment, the aperture may have an elongated shape. A bar may protrude out transversely at the end of the locking pin 76 where the bar is sized to fit through the aperture. The locking pin 76 may be rotated to align the bar with the aperture having the elongated shape, thereby allowing the locking pin 76 to escape out of the aperture. On the other hand, the pivotal piece 44 may be at a locked position, when the locking pin 76 is received by the aperture and rotated further to misalign the bar about the aperture.
[0039] As indicated previously, the detachable tablet holder 20 apparatus of the present invention includes fixed but pivotal support legs 24 . Reference may now be made to further fragmentary views of FIGS. 6 and 7 showing the base of the support legs 24 . FIG. 6 illustrates the support legs 24 in a locked upright position, while FIG. 7 shows the support legs 24 disengaged and pivoted to a stowed position wherein the support legs 24 extends substantially alongside of the stroller rails 18 . The arrow 77 in FIG. 7 illustrates the direction of pivoting. The support legs 24 include a base end 80 and a pivot arm 82 . FIGS. 6 and 7 also illustrate a pivot stop 84 . The pivot stop 84 , as illustrated in FIG. 6 , has a pad 85 that engages the base 80 and a disengageable pad 86 that is locked under the pivot arm 82 . The pivot arm 82 may be attached to the rail 80 at a pivot location 87 . The pivot stop 84 is supported in a pivotal manner at 88 . There is also included a slide ring 89 attached to the pivot arm 82 . In FIG. 6 the slide ring 89 is shown at its uppermost position with the pivot arm 82 pivoted and locked in position so that the support legs 24 are in an upright position such as the position illustrated also in FIG. 1 .
[0040] In order to pivot the support legs 24 to a downward position, reference may now be made to FIG. 7 . For that purpose, the pad 86 may be screwed down so as to disengage from the pivot arm 82 allowing the pivot arm 82 to pivot. This causes the slide ring 89 to slide along the base 80 to its lowermost position as illustrated in FIG. 7 . This pivoting action in the direction of arrow 77 stows the support legs 24 to a position directly adjacent to the stroller rail 18 . The adjustment illustrated in FIGS. 6 and 7 can be made with respect to both of the oppositely disposed support legs 24 which are meant to be supported in the same position depending upon whether in the operative position or in the stowed position.
[0041] FIG. 5 , in particular, illustrates the manner in which the platform 28 of the detachable tablet holder 20 may be disengaged from the support legs 24 . This disengagement is illustrated by means of the arrow 92 in FIG. 5 . The removable portion 26 may then be totally removed on both sides of the platform 28 so that access is had to the seated area of the stroller 10 . This enables the child to be seated or removed from the seated area. After the child is in place, then the platform 28 may be secured at the support legs 24 such as in the position illustrated in FIG. 4 . Adjustment and height of the platform 28 is possible by means of the locking ring 34 rotated in the direction of arrow 35 as depicted in FIG. 4 .
[0042] Turning back to FIG. 2 , an embodiment describing an assembly of the tablet 22 and the support frame 64 is shown. The tablet 22 may comprise a left edge, a right edge opposite to the left edge, a front face, and a back face opposite to the front face. In one embodiment, the support frame 64 may comprise the one side end 67 contacting the tablet 22 at an upper portion of the left edge, forming a first end structure. The one side end may be urged against the upper portion of the left edge when the support frame 64 is at a fixed position. The one side end may further contact the tablet 22 at a lower portion of the left edge, forming a second end structure, which may be urged against the one side end 67 when the support frame 64 is at the fixed position. The first end structure and the second end structure may further extend towards the right edge over the front face, forming L-shape end structures, which may prevent the tablet 22 from escaping away from the support frame 64 .
[0043] In another embodiment, the support frame 64 may comprise an arm extending from the back of the support frame 64 away from the one side end 67 and towards the right edge. The arm may contact the right edge, forming a third end structure, which may be urged against the right edge when the support frame 64 is at the fixed position. The third end structures may further extend towards the left edge over the front face, causing the plurality of third end structures to appear L-shape, which may prevent the tablet 22 from escaping away from the support frame 64 .
[0044] Turning now to FIG. 8 a view of an underside of an embodiment of a platform 128 is provided. The platform is connected to support legs 103 by 90 degree connectors 101 (or similar angled joint connector) to cross-bar 102 . Cross bar supports the platform 128 to whatever the platform is connected to. A pair of U-joints 104 may connect cross-bar 102 directly to the platform 128 , though it should be understood that any connection may be employed. Cross-bar 102 is shown here as a two part bar slideably inserted into a central tube. This central tube comprises a plurality of apertures 105 —in this case, three rows of non-aligned apertures 105 . Spring loaded pins 106 extend from each side end of the cross bars 102 . These pins 106 are configured to engage with the apertures 105 at varying positions, to allow support legs 103 to be angled and spaced to a variety of positions. As such, the support legs may be parallel or not, may be positioned at the same lateral position, or not, and further, this configuration allows platform 128 to have its angle adjusted forward or backward, depending on desired configuration. In this embodiment, the tablet holder support legs 102 may be configured to not only attach to a stroller, but can also attach to any other device such as a wheelchair, a standard chair, a table, stool, desk, and the like.
[0045] FIGS. 9 , 10 and 11 , show another embodiment of the tablet holder. This embodiment is configured to attach not only to a stroller but to any other device, including, but not limited to a wheelchair, a standard chair, a table, stool, desk, and the like. Platform 128 has cross-bar or bars 102 connected to its bottom. It should be understood that in some embodiments, the underside of platform 128 may be configured as shown in FIG. 8 . Cross bars 102 are connected at each end to joint 107 . Which may be adjustable to change the angle between cross bar 102 and support leg 103 . A connector assembly is comprised of a slideable and pivotable connector 111 . A slide bar 108 connects bar 110 to another connector 111 , creating a triangular and adjustable base for connector 109 . Slide bar 108 comprises a channel along its length with a peg movable along the channel. This peg is connected to bar 110 which is pivotally connected to leg 103 via connector 111 . As such, clamp connector 109 may be moved and rotated to any number of different positions and orientations allowing for its connection to many different surfaces or structures. It should be understood that platform 128 , in most embodiments may further comprise the tablet and connector structure as discussed above and shown in FIG. 2 , 3 , and other figures.
[0046] Further shown in FIG. 9 is the platform 128 having a generally U shaped receiving slot formed as a protrusion from the top face of the platform, having a reduced diameter through a channel, and increased diameter at the receiving section. The channel is configured to slideably receive the frame, such that the frame is removable by sliding out of the channel, and held securely in place when within the channel. This structure allows the frame and its connected structure to be removable from the platform, and securely attachable to the platform. The receiving slot further comprises two portions along its height, the first portion having a width large enough to receive the frame, and the second portion above the first portion having a width smaller than the width of the frame, such that the frame cannot pass upward through the channel, and can only slide outward on the open end of the U-shaped channel.
[0047] Having now described a limited number of embodiments of the present invention, it should now be apparent to those skilled in the art that numerous other embodiments and modifications thereof are contemplated as falling within the scope of the present invention, as defined by the appended claims. | The present disclosure concerns a tablet holder securing a tablet to a stroller, chair, table, or the like. The tablet holder involves a multiple adjustable mechanisms to accommodate different size of the tablet and viewing angles. The tablet holder provides a secure platform for the user to interact with the tablet, and it is conveniently foldable and can be disassembled while not in use. | 5 |
BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to a dewatering arrangement at the forming of a web from fibrous particles suspended in water. The invention particularly refers to a device applicable to the wet end of a papermaking machine.
In SE-PS No. 7904555-5 a method of forming paper is described where the forming process proper takes place between a flexible upper lip and an unsupported portion of the wire over an open suction box. The flexible upper lip is an extension of the stationary upper lip on a head box. This implies that the stock jet from the head box is directed downward to the sheet forming zone by the flexible lip, and that during the entire sheet forming process the stock layer is clearly defined as to its form. The absence of disturbances in the surface layer of the stock jet is a prerequisite for the grammage variations in the paper made to be maintained on a lower level. An additional improvement of the uniformity of the paper is obtained when the forming takes place with the influence of viscous shearing forces between the stationary upper lip and the movable wire. Due to the effect of the pressure difference between the atmospheric pressure and the low pressure in the suction box, the wire moves in a curved path. The flexible upper lip adapts itself to the form of the wire and thereby also assumes curved form. For producing the vacuum in the suction box, the box must be sealed on the sides. This sealing is made by means of adjustable sealing strips. This implies that, irrespective of the configuration of these strips, the wire will be curved three dimensionally along the sides over the suction box. The flexible upper lip, which should have a certain bending resistance, cannot fully adapt itself to the three dimensional form of the wire. Hereby certain edge disturbances can arise in the paper sheet formed, which may cause problems for the operativeness of the papermaking machine. These problems can be neglected for low paper grammages and for stocks easy to dewater, because only small pressure differences over the wire are required, resulting in a small downward deflection of the wire. For higher grammages, however, and for stocks more difficult to dewater higher pressure differences and also longer dewatering distances are required, which together result in a substantial downward deflection of the wire and consequently also in increased edge disturbances in the sheet formed.
A further disadvantage of the method is that great amounts of energy are required for generating the vacuum in the suction box.
One way of avoiding the aforesaid disadvantages, but still utilizing the advantages, is to generate the necessary dewatering pressure by means of an overpressure above the flexible lip over an unsupported portion of the wire. In this case the upper lip and wire are loaded in their entire extension across the papermaking machine, whereby only a two dimensional deflection is caused. The overpressure can be produced by means of an air cushion or a rigid pressure plate, which is designed so as to face the stock with a convex surface. In the case of a convex pressure plate, the plate can be utilized together with a flexible upper lip or it can entirely replace the same. Such an arrangement is proposed in U.S. Pat. No. 4,416,730.
In the U.S. patent the pressure plate (in said U.S. Pat. No. 4,416,730 called slide shoe) is described generally to have a surface curved convex toward the stock. The pressure plate further is rigidly connected to the head box and can be regarded as an extension of the upper (or lower lip) of the head box. In embodiments of the patent, the stock jet is transported after the outlet opening along a convex surface where the opposed surface, at least for a certain distance, is a free liquid surface. The disadvantage of this method will be described in greater detail below where also the invention, on which this application is based, will be described.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the rigid pressure plate showing the concave and convex sections, the head box, the stock jet and wire supporting roll;
FIG. 2 shows the concave and convex sections with respect to the hydrostatic pressure developed under various points of the plate;
FIG. 3 is an additional embodiment of the pressure plate including a straight section between the concave and convex sections;
FIG. 4 is another embodiment of the pressure plate with an additional convex section;
FIG. 5 is a further embodiment of the pressure plate with the concave and convex sections physically separated; and
FIG. 6 is a side view of a series arrangement of a plurality of the web forming devices of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 a pressure plate 1 is shown, which substantially consists of two sections, a first one 1a, which towards the stock has a concave surface with a radius of curvature R 1 and extension L 1 , and a second section 1b, which faces the stock with a convex surface with a radius of curvature R 2 and extension L 2 . The rigid pressure plate 1 joins a roll 2, in such a manner, that the shortest distance between the pressure plate and roll is located at the inflection point of the pressure plate, i.e. where the curvature of the pressure plate transforms from concave to convex. The roll 2 supports a wire 3. From the outlet opening 4 on a head box a stock jet 5 is sprayed substantially tangentially inward to the concave surface 1a of the pressure plate. The stock jet follows the concave surface on the pressure plate downward to the inflection point where it is enclosed between the pressure plate and wire. Along the convex surface of the pressure plate the sheet forming zone proper is located, where the dewatering takes place.
In order to additionally illustrate the sheet forming conditions, in FIG. 2 the hydrostatic pressure is shown which was measured beneath the pressure plate on an experimental papermaking machine during a test run. The essential measures of the pressure plate are indicated in mm in the Figure. For the test, the papermaking machine was run at a speed of 400 m/min. The jet speed V out of the head box was 480 m/min, and the outlet opening on the head box was 10 mm, the thickness H of the jet was consequently also 10 mm. At its transport along the concave surface on the pressure plate, the jet is influenced by the centrifugal force. The static pressure produced by this force on the surface of the pressure plate can be calculated according to the equation as follows: ##EQU1## where P=static pressure (Pa)
ρ=water density (kg/m 3 )
V J =jet speed (m/s)
H=jet thickness (m)
R 1 =curvature radius of concave surface (m)
The advantage of causing the jet from the head box to be transported along a concave surface down to the sheet forming zone is apparent. Due to the pressure build-up along the pressure plate, air is prevented from being sucked in between the plate and jet. It is hereby possible to separate the pressure plate from the head box, which can be advantageous from a design point of view.
Furthermore, as the static pressure increases inward to the pressure plate, air possibly included in the stock is transported outward to the free surface of the jet. A third advantage is that the centrifugal force has a damping effect on disturbances at the free surface of the jet, so that a jet of uniform thickness is delivered down to the sheet forming zone.
When the transport of a stock jet along a curved concave surface, as described above, is considered, correspondingly to take place along a convex surface, it is readily understood that the clear advantages turn into obvious disadvantages.
At the transport of a stock jet along a convex surface, analogous to the aforesaid, a pressure arises along the surface of the pressure plate, but the pressure has a reversed sign, i.e. it is a vacuum instead of an overpressure. When there is a vacuum along the surface of the pressure plate, there is risk of air being sucked in between plate and jet. One prerequisite of preventing this to take place is, that the pressure plate is connected air-tight to the head box.
Under conditions prevailing in practice it is next to impossible to avoid air admixture to the stock. At a convex surface, i.e. where the pressure in the stock layer decreases inward to the pressure plate, the air migrates to the pressure plate where an air layer rapidly is built up, due to which the jet is separated from the pressure plate.
Contrary to the aforesaid applying to the concave surface, the centrifugal force influences a stock jet moving along a convex surface in such a manner, that disturbances which are present at the free liquid surface are increased.
Conclusively, a configuration of the pressure plate according to the patent cited above implies, that the stock jet at its arrival at the sheet forming zone very probably has been broken up. This will result in a paper reflecting the quality of the stock jet.
In close connection to the inflection point, according to FIG. 2, the stock jet is enclosed between the pressure plate and wire. Along the convex surface of the pressure plate the wire will press against the pressure plate and the stock jet lying therebetween. The size of this pressure depends on the tensile stress T in the wire and the curvature radius of the wire, which radius substantially corresponds to the curvature radius R 2 of the pressure plate. This relation is described by the equation as follows:
P=T/R.sub.2 (2)
where
P=static pressure (Pa)
T=wire tension (N/m)
R 2 =curvature radius of convex surface (m)
As appears from FIG. 2, the pressure measured along the entire length of the pressure plate agrees pretty well with the theoretical ones.
The pressure measured beneath the convex portion of the pressure plate corresponds substantially to the dewatering pressure. The dewatering capacity of a pressure plate in a first approximation can be set proportionally to the dewatering impulse I according to: ##EQU2## where I=dewatering impulse (Pa.s)
P t =size of the pressure pulse at time t (Pa)
τ=duration of pressure pulse (s)
The equation (3) can be developed according to ##EQU3## where u w =wire speed (m/s)
The dewatering capacity, thus, is proportional to the surface below the pressure curve according to FIG. 2.
Experiences a.o. from papermaking with twin wire machines have shown, that the uniformity of the paper depends on the appearance of the pressure pulse. This pulse, as has become apparent from the aforesaid, can be affected by means of the radius of curvature of the convex portion of the pressure plate. In the above examples the convex portion of the pressure plate has had a uniform curvature radius. Within the scope of the present invention nothing objects to the curvature radius varying along the dewatering distance. Two embodiments thereof are shown in the following.
FIG. 3 shows a pressure plate according to FIG. 1, but where between the concave and convex sections a straight section 1c with an extension L 3 is provided. This pressure plate yields a pressure pulse where the pressure slowly increases up to the level corresponded by P=T/R 2 .
FIG. 4 again shows a pressure plate according to FIG. 1, but where between the aforesaid first and second section a third convex section 1d is provided. The curvature radius R 3 of this section is smaller than the curvature radius R 2 in the subsequent section. By this design a pressure pulse is yielded which rapidly rises to a level corresponding to P=T/R 3 whereafter the pressure drops to a level corresponding to P=T/R 2 .
FIG. 5 shows an embodiment, which also is comprised within the scope of the present invention. The configuration seen here is similar to that in FIG. 4, but the first concave section 1a of the pressure plate is physically separated from the convex sections of the pressure plate. There is no significant difference in respect of the effect on the stock jet, because a flexible plate 6 is rigidly connected to the first concave section and extends along the concave surfaces so as to connect the flow of the concave section with that of the convex sections. The flexible plate has a total length corresponding to the length of the convex sections and is attached so on the concave section, and the convex sections geometrically are so arranged that there is a soft transition for the stock jet between the concave section and the flexible plate, which assumes the convex shape of the subsequent convex sections. The arrangement according to this Figure has the advantage, that the length of the dewatering zone can be varied, for example, by the position of a guide roll 7, which affects the direction of the wire after the pressure plate. By changing the direction of the wire, the enclosing by the wire of the convex surface of the pressure plate, and thereby the dewatering capacity, can be varied. The combination of the flexible plate and the convex portion of the pressure plate renders it possible to utilize a limited portion of the convex surface of the pressure plate without the risk of destroying the sheet formed in a diverging gap between plate and wire.
The aforedescribed devices according to the invention, preferably together with separate head boxes, can be attached in series in a wire course for forming multiply paper.
FIG. 6 shows an example of such an arrangement.
Instead of forming an additional fibre layer in a second step, the arrangement can be used for applying on a previously formed layer, for example, filler, e.g. clay, or a second step can imply that a chemical solution is applied and dewatered, for example washing liquor in a wire washer room. | The device comprises a head box with a nozzle for applying a pulp suspension on a wire located below the nozzle. A pressure plate is located after the nozzle over the pulp suspension. The pressure plate comprises a concave formed portion, against which the pulp suspension is sprayed, and a subsequent convex formed portion. The fiber web is formed in a forming zone where dewatering is effected in that the convex portion of the pressure plate and an unsupported portion of the wire are pressed against each other. | 3 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/271,053, filed Dec. 22, 2015, which application is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] Utility lines for water, electricity, gas, telephone, and cable television are often run underground for reasons of safety and aesthetics. Horizontal directional drilling (HDD) is often used for placement of such utility lines. In a typical horizontal directional drilling sequence, the horizontal directional drilling machine drills a hole into the ground at an oblique angle and then drives a series of interconnected drill rods (i.e., a drill string) along a substantially horizontal path to create a horizontal hole. It is common to attach a utility line or other conduit to the drill string so that it is dragged back through the hole.
[0003] A typical horizontal directional drilling machine includes a frame on which is mounted a drive mechanism that can be slidably moved along the longitudinal axis of the frame. The drive mechanism is adapted to rotate the drill string about its longitudinal axis. Sliding movement of the drive mechanism along the frame, in concert with the rotation of the drill string, causes the drill string to be longitudinally advanced into or withdrawn from the ground.
[0004] A horizontal directional drilling machine also includes a rod box (i.e., a rack or magazine) for storing rods (i.e., pipes or other elongated members) used to make the drill strings. The more drill rods that are stored on the horizontal directional drilling machine, the longer the horizontal directional drilling machine can operate continuously. Further, storing drill rods on the horizontal directional drilling machine makes transportation and operation of the machine more efficient.
[0005] However, horizontal directional drilling machines are constrained by certain size requirements, and, therefore, the size of the rod box on the horizontal directional drilling machine is also constrained to certain size requirements. For example, the height of the horizontal directional drilling machine can be limited based on the location of the machine's center of gravity so as to prevent instability of the machine. Further, the width of the rod box, and the horizontal directional drilling machine in general, is also important as the horizontal directional drilling machine will need to be moved (i.e., driven) to the worksite from a trailer. Therefore, the ability to fit through certain narrow openings, such as gates, is important to the usefulness of the horizontal directional drilling machine.
[0006] Therefore, improvements are needed to increase or at least maintain (e.g., relative to a standard rod box) the capacity of rod boxes while also maintaining certain horizontal directional drilling machine dimensions.
SUMMARY
[0007] The present disclosure relates generally to a pivotable rod box for a horizontal directional drilling (HDD) machine. In one possible configuration, and by non-limiting example, the rod box is pivotable between a stowed position and an operational position, where the stowed position decreases the overall width of the HDD machine.
[0008] In a first aspect of the present disclosure, an HDD machine for drilling a string of drill rods into the ground is disclosed. The HDD machine includes a frame that supports a drill head track that defines a longitudinal axis. The HDD machine also includes a drill head mounted on the track, and the drill head includes a rotational rod drive. The HDD machine includes a thrust mechanism for moving the drill head along the longitudinal axis of the drill head track between a retracted position adjacent a first end of the drill head track and an extended position adjacent an opposite second end of the track. The HDD machine also includes a rod box for holding a plurality of drill rods. The rod box has an upper end and a lower end and is pivotally connected to the frame at a pivot axis positioned adjacent the lower end of the rod box. The pivot axis is oriented to extend along the longitudinal axis of the track, and the rod box is pivotally movable about the pivot axis between a stowed position and an operational position. The rod box overhangs the longitudinal axis of the drill head track and obstructs movement of the drill head from the retracted position to the extended position when in the stowed position. The rod box is laterally offset from a region above the longitudinal axis drill head track when in the operational position so as to not interfere with movement of the drill head along the longitudinal axis. The rod box has a load/unload opening adjacent the upper end of the rod box for allowing the drill rods to be manually loaded into the rod box and manually removed from the rod box. The rod box also includes a first side that faces toward the drill head track and a second side that faces away from the track. The load/unload opening of the rod box is positioned adjacent the first side and the rod box defines a width that extends between the first and second sides. The rod box is also tapered such that the width is larger adjacent the upper end of the rod box as compared to the lower end of the rod box. The rod box can accommodate more drill rods across the width adjacent the upper end as compared to adjacent the lower end.
[0009] In a second aspect of the present disclosure, an HDD machine for drilling a string of drill rods into the ground is disclosed. The HDD machine includes a frame that supports a drill head track that defines a longitudinal axis, the longitudinal axis residing in a vertical reference plane generally perpendicular to the ground. The HDD machine also includes a drill head mounted on the track, and the drill head includes a rotational rod drive. The HDD machine further includes a thrust mechanism for moving the drill head along the longitudinal axis of the drill head track between a retracted position adjacent a first end of the drill head track and an extended position adjacent an opposite second end of the track. The HDD machine includes a rod box for holding a plurality of drill rods. The rod box has a generally triangular shaped cross-section and a longitudinal axis generally parallel to the longitudinal axis of the frame. The rod box is pivotally connected to the frame and movable between a stowed position and an operational position. When in the operational position, drill rods can be loaded into the rod box and removed from the rod box during a drilling operation. When in the operational position, the furthest portion of the rod box from the vertical reference plane is located at a distance D 1 therefrom, and when in the stowed position, the furthest portion of the rod box from the vertical reference plane is located at a distance D 2 therefrom. The distance D 1 is greater than the distance D 2 .
[0010] A variety of additional aspects will be set forth in the description that follows. The aspects can relate to individual features and to combinations of features. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the embodiments disclosed herein are based.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The following drawings are illustrative of particular embodiments of the present disclosure and therefore do not limit the scope of the present disclosure. The drawings are not to scale and are intended for use in conjunction with the explanations in the following detailed description. Embodiments of the present disclosure will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements.
[0012] FIG. 1 illustrates a perspective view of an HDD machine in an inactive position, according to one embodiment of the present disclosure;
[0013] FIG. 2 illustrates a side view of the HDD machine of FIG. 1 in the inactive position;
[0014] FIG. 3 illustrates a perspective view of the HDD machine of FIG. 1 in a working position;
[0015] FIG. 4 illustrates a side view of the HDD machine of FIG. 1 in a working position;
[0016] FIG. 5 illustrates a front view of the HDD machine of FIG. 1 in the inactive position;
[0017] FIG. 6 illustrates a front view of the HDD machine of FIG. 1 in a working position;
[0018] FIG. 7 illustrates a perspective view of a drive assembly, a frame, and a rod box in a stowed position of an HDD machine, according to one embodiment of the present disclosure;
[0019] FIG. 8 illustrates a perspective view of the drive assembly, the frame, and the rod box of FIG. 7 with the rod box in an operational position;
[0020] FIG. 9 illustrates a rear perspective view of the drive assembly, the frame, and the rod box of FIG. 7 with the rod box in a stowed position;
[0021] FIG. 10 illustrates a rear perspective view of the drive assembly, the frame, and the rod box of FIG. 7 with the rod box in an operational position;
[0022] FIG. 11 illustrates a top view of the drive assembly, the frame, and the rod box of FIG. 7 with the rod box in the stowed position;
[0023] FIG. 12 illustrates a top view of the drive assembly, the frame, and the rod box of FIG. 7 with the rod box in the operational position;
[0024] FIG. 13 illustrates a front view of the drive assembly, the frame, and the rod box of FIG. 7 with the rod box in the stowed position;
[0025] FIG. 14 illustrates a top view of the drive assembly, the frame, and the rod box of FIG. 7 with the rod box in the operational position;
[0026] FIG. 15 illustrates a perspective view of a rod box, according to one embodiment of the present disclosure;
[0027] FIG. 16 illustrates a perspective view of a rod box of FIG. 15 empty of drill rods;
[0028] FIG. 17 illustrates a side view of the rod box of FIG. 15 ;
[0029] FIG. 18 illustrates a back end view of the rod box of FIG. 15 in the stowed position;
[0030] FIG. 19 illustrates a front end view of the rod box of FIG. 15 in the stowed position;
[0031] FIG. 20 illustrates a back end view of the rod box of FIG. 15 in the operational position;
[0032] FIG. 21 illustrates a front end view of the rod box of FIG. 15 in the operational position;
[0033] FIG. 22 illustrates a back end view of a rod box in the stowed position, according to one embodiment of the present disclosure; and
[0034] FIG. 23 illustrates a back end view of the rod box of FIG. 22 in the operational position.
DETAILED DESCRIPTION
[0035] Various embodiments will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the appended claims.
[0036] The HDD machine disclosed herein has several advantages. Specifically, the rod box of the present disclosure is pivotally connected to the HDD machine, allowing the rod box to move from a stowed position to an operational position. When in the stowed position, the rod box allows the HDD machine to maintain a narrow width (e.g., narrow enough to pass through a yard gate (typically about 36 or 42 inches wide)), while still storing a substantial amount of drill rods on the HDD machine. When moving from the stowed position to the operational position, the rod box pivots away from the HDD machine so as to allow full operation of the HDD machine. More generally, the pivoting rod box of the present disclosure allows the other components of the HDD machine to be increased in size (i.e., the engine) while still maintaining sufficient drill rod storage and size requirements for the HDD machine. Furthermore, the present HDD machine provides a lower center of gravity, both in the operational and stowed positions, thereby minimizing the tendency for instability.
[0037] FIGS. 1-2 show the HDD machine 100 in an inactive position. The HDD machine 100 includes a front end 102 and a rear end 104 . The HDD machine 100 also includes a frame 106 , a front operator's station 108 , a rear operator's station 110 , a pair of tracks 112 , a drilling assembly 114 , an engine housing 116 , and a rod box 118 . When in the inactive position, the HDD machine 100 can be transported by trailer, driven to a worksite, or parked and stored between drilling operations. The inactive position allows the HDD machine 100 to maintain a compact footprint while also allowing the HDD machine 100 to be in an inactive position to prevent accidental or unintended operation of the HDD machine 100 . In one variation, the compact footprint includes an overall inactive machine width of about 36 inches or less, thus facilitating navigation through a typical yard or garden gate. In another variation, the compact footprint includes an overall inactive machine width of about 42 inches or less, thus facilitating navigation through a typical yard or garden gate When moving the HDD machine 100 , an operator can control the movement of the pair of tracks 112 , and therefore the HDD machine 100 , by driving the HDD machine 100 from the rear operator's station 110 .
[0038] FIGS. 3-4 show the HDD machine 100 in a working position. In the working position, the HDD machine 100 is configured to perform a drilling operation that includes driving a drill string underground along a generally horizontal path at the worksite. In the depicted embodiment, certain components of the HDD machine 100 are configured to move when the HDD machine 100 moves from the inactive position to the working position. In some embodiments, the front operator's station 108 is capable of swinging away from the HDD machine 100 so as to allow an operator a clear line of sight to the drilling assembly 114 and also allow the operator access to a plurality of different controls and to the rod box 118 . The drilling assembly 114 is configured to tilt toward the front end 102 of the HDD machine 100 when the HDD machine 100 moves from the inactive position to the working position. This allows the drilling assembly 114 to deliver a drill rod into a ground surface 115 at the worksite at an oblique angle. Finally, in the depicted embodiment, the rod box 118 is pivotally movable relative to the frame 106 , so as to allow the rod box 118 to pivot away from the HDD machine 100 when the HDD machine 100 moves from the inactive position to the working position.
[0039] The frame 106 of the HDD machine 100 is configured to support the operator's stations 108 , 110 , drilling assembly 114 , engine housing 116 , and rod box 118 . The frame 106 provides structural support to the HDD machine 100 .
[0040] The front operator's station 108 is positioned near the front end 102 of the HDD machine 100 . The front operator's station 108 is configured to allow an operator to control the operation of the HDD machine 100 from a seated position. The rear operator's station 110 is positioned near the rear end 104 of the HDD machine 100 and allows the operator to operate the HDD machine 100 from a standing position.
[0041] The tracks 112 are configured to allow the operator to move the HDD machine 100 . In some embodiments, the tracks 112 have a width that is less than a trailer width so that the HDD machine 100 may be transported long distances via a trailer on public roads. In some embodiments, the HDD machine 100 may have a width so as to be simultaneously transported adjacent to other machines on a flatbed trailer.
[0042] The drilling assembly 114 is configured to provide thrust and rotational force to a series of drill rods (i.e., a drill string) during a drilling operation. Additionally, the drilling assembly 114 is configured to add and remove drill rods to and from the drill string. The drilling assembly 114 is powered by engine components (not shown) located within the engine housing 116 .
[0043] The engine housing 116 is configured to cover the engine components that enable the HDD machine 100 to operate. The engine components can include a prime mover, and its components, and a hydraulic system and its components. The prime mover can be an internal combustion engine, electric motor, or other similar hybrid-type engine. In some embodiments, the engine housing 116 is mounted to the frame 106 of the HDD machine 100 . The engine housing 116 is configured to include a multitude of panels, some of which may be removable.
[0044] The rod box 118 (i.e., a magazine or rack), which will be discussed in more detail with respect to FIG. 13-18 , is configured to store a plurality of drill rods. The rod box 118 is also configured to allow drill rods to be readily removed and added to the rod box 118 during a drilling operation. In some embodiments, the rod box 118 can store a quantity of drill rods to allow a drilling operation to be completed without the need to retrieve drill rods from an additional storage location. In some embodiments, the rod box 118 can store about 150 feet of drill rods.
[0045] FIG. 5 shows a front view of HDD machine 100 in the inactive position. In the inactive position, the HDD machine 100 has a first machine width of W 1 , which may also be considered to be a stowed or compact width W 1 . In some embodiments, W 1 is a width that is less than about 36 inches. In some embodiments, the width W 1 is less than the width of a standard garden/yard gate. FIG. 6 shows a front view of the HDD machine 100 in the working position. As shown, the HDD machine 100 has a second machine width of W 2 , which may be considered the expanded or working width W 2 . W 2 is greater than W 1 . In the depicted embodiment, W 2 is measured from the widest portion of the engine housing 116 to the widest portion of the rod box 118 . In some embodiments, the front operator's station 108 is also movably pivotable in a direction laterally away from the HDD machine 100 , which can also increase the HDD machine 100 's working width W 2 .
[0046] FIGS. 7-8 show perspective views of the drilling assembly 114 , the rod box 118 , and the frame 106 . In FIG. 7 , the rod box 118 is shown in the stowed position. In FIG. 8 , the rod box 118 is, in turn, shown in the operational position. FIGS. 9-10 show rear perspective views of the drilling assembly 114 , the rod box 118 , and frame 106 . In FIG. 9 , the rod box 118 is shown in the stowed position. In FIG. 10 , the rod box 118 is shown in the operational position. The drilling assembly 114 includes a drill head 120 , a spindle 122 , a drill head track 124 , and a vise/anchor assembly 126 . The drill head 120 provides thrust and rotational power to the spindle 122 and moves a drill rod 128 along a longitudinal axis A of the drilling assembly 114 .
[0047] When performing a drilling operation, first, the rod box 118 is moved to the operational position. The drill rod 128 is then removed from the rod box 118 and connected to the spindle 122 . Once connected to the spindle 122 , the drill head 120 travels along the drill head track 124 , moving the drill rod 128 in a direction toward the front 102 of the HDD machine 100 . In some examples, the drill head 120 can travel along the drill head track 124 via gears (i.e., a rack and pinion gear). In other examples, the drill head track 124 can include cylinders or cables to propel the drill head 120 along the drill head track 124 . Once the drill head 120 is adjacent the vise/anchor assembly 126 , the drill rod 128 is removed from the spindle 122 , and the drill head 120 travels backward in a direction away from the front 102 of the HDD machine 100 along the drill head track 124 so that another drill rod can be added. Such a process is repeated until the drill string is complete. Further, while no drill rod loading mechanism is shown in the FIGS., in some embodiments, a drill rod loading mechanism can be utilized to move drill rod from the rod box 118 to the drilling assembly 114 .
[0048] FIGS. 11-12 show a top view of the drilling assembly 114 and the rod box 118 . FIG. 11 shows the rod box 118 in the stowed position, and FIG. 12 shows the rod box 118 in the operational position. As shown in FIG. 11 , when pivoted into the stowed position, the rod box 118 blocks the movement of the drill head 120 along the drill head track 124 toward the vise/anchor assembly 126 . Specifically, the rod box 118 overlaps the longitudinal axis A of the drilling assembly 114 when the rod box 118 is in the stowed position. Further, when in the stowed position, the furthest portion of the rod box 118 from the longitudinal axis A is a distance D 2 . Due to the rod box 118 being generally low in height compared to the HDD machine 100 , and the fact that the rod box 118 overlaps the longitudinal axis A when in the stowed position, the rod box 118 helps to position the HDD machine 100 's center of gravity closer to the ground and closer to the longitudinal axis A. This can be important, for example, when transporting the HDD machine 100 and also when performing drilling operations on uneven ground or a surface with a grade.
[0049] As shown in FIG. 12 , the rod box 118 pivots about a pivot axis B proximate a bottom or base (not labelled) of the rod box 118 , so as to move between the stowed position and the operational position thereof, and, when moved into the operational position, the rod box 118 does not overlap the longitudinal axis A. Not being overlapped with the longitudinal axis A allows the drill head 120 to travel along the drill head track 124 . Further, when in the operational position, the furthest portion of the rod box 118 from the longitudinal axis A is a distance D 1 . As shown, D 1 is greater than D 2 . Also, the pivot axis B and the longitudinal axis A are generally parallel.
[0050] FIG. 13 shows a front view of the drilling assembly 114 and the rod box 118 in the stowed position. FIG. 14 shows a front view of the drilling assembly 114 and the rod box 118 in the operational position. As shown, the rod box 118 is attached to the frame 106 with a pair of arms 130 .
[0051] FIGS. 15-21 show the rod box 118 detached from the HDD machine 100 . The rod box 118 is configured to hold a plurality of drill rods in a position that is in close proximity to the drilling assembly 114 . The rod box 118 has an upper end 132 and a lower end 134 and is pivotally attached at a pivot connection 135 to the arms 130 at the lower end 134 so as to be movable about pivot axis B. Further, the rod box 118 has a generally open side 136 , a closed side 138 , a front end 140 , a back end 142 , and a partially open top side 144 . The rod box 118 has a generally triangular cross section, and, in some embodiments, the rod box 118 is tapered so that the width is larger adjacent the upper end 132 of the rod box 118 as compared to the lower end 134 of the rod box 118 . Additionally, the upper end 132 , via the partially open top side 144 , provides user access to the drill rods stored within the rod box 118 .
[0052] FIG. 16 shows the rod box 118 empty of drill rods. The rod box 118 has an open interior structure that does not include structure defining any pre-defined rows or columns for the drill rods.
[0053] The generally open side 136 of the rod box 118 is configured to face toward the drill head track 124 of the drilling assembly 114 . The generally open side 136 includes open side elements 136 a and 136 b which serve to retain the drill rods within the rod box 118 , while still providing a substantially open profile therebetween. By having a generally open side 136 and a partially open top side 144 as part of the overall rod box construction, the rod box 118 is able to substantially retain the drill rods yet still establish a rod access zone 137 . In some embodiments, the rod access zone 137 corresponds with the open top side 144 . In other embodiments, the rod access zone 137 can correspond to a portion of the open side 136 . Via the rod access zone 137 , the operator of the HDD machine 100 can manually remove and replace drill rods to and from the rod box 118 during a drilling operation. Specifically, the operator can remove and replace drill rods from the rod access zone 137 and do so while operating the HDD machine 100 from the operator's station 108 , as shown in FIG. 3 .
[0054] FIGS. 18-19 show the ends 140 , 142 of the rod box 118 when the rod box 118 is in the stowed position. When the rod box 118 is in the stowed position, the generally open side 136 is angled relative to vertical, while the closed side 138 is generally vertical. FIGS. 20-21 show the ends 140 , 142 of the rod box 118 when the rod box 118 is in the operational position. When the rod box 118 is in the operational position, the open side 136 is generally vertical while the closed side 138 is generally angled relative to vertical.
[0055] As shown, the arms 130 a / 130 b include positive stops to prevent the over-rotation of the rod box 118 when moving the rod box 118 between the stowed and operational positions. Specifically, the arm 130 a that is positioned near the back end 142 of the rod box 118 includes a channel 146 , with the shape of the channel 146 inherently posing a pair of travel limits. The back side 142 of the rod box 118 includes a peg 148 that is configured to travel within the travel limits (i.e., first and second sides 150 , 152 ) established by the channel 146 of the arm 130 a . As shown in FIG. 18 , the peg 148 is positioned at a first side 150 of the channel 146 when the rod box 118 is in the stowed position. When the rod box 118 is moved to the operational position shown in FIG. 19 , the peg 148 slides within the channel 146 and is positioned at a second end 152 of the channel 146 .
[0056] Arm 130 b positioned near the front end 140 of the rod box 118 includes a stowed pocket 154 and an operational pocket 156 . The pockets 154 , 156 are configured to interface with a movable lever 158 that is movably secured to the front end 140 of the rod box 118 . The movable lever 158 is positioned within a lever channel 160 and also includes a handle 162 . In the depicted example, the lever channel 160 is defined by a bracket 161 attached to the rod box 118 . In the depicted embodiment, the lever 158 is spring loaded and biased in a downward direction toward the arm 130 b by a spring 164 . As shown in FIG. 19 , when the rod box 118 is in the stowed position, the lever 158 is positioned within the stowed pocket 154 of the arm 130 b . When moved to the operational position, as shown in FIG. 21 , the lever 158 is moved in an upward direction by the operator and then positioned within the operational pocket 156 of the arm 130 b . The stowed and operational pockets 154 , 156 of arm 130 b combined with the movable lever 158 allow the rod box 118 to be locked in either the stowed or operational positions.
[0057] While movement of the rod box 118 disclosed herein is described as being controlled manually by the operator, in other embodiments, the movement of the rod box 118 can be controlled by a hydraulic or pneumatic actuator.
[0058] FIGS. 22 and 23 show a rod box 218 , according to another embodiment of the present disclosure. FIG. 22 shows a front end 240 of the rod box 218 when the rod box 218 is in the stowed position. FIG. 23 shows the rod box 218 in an operational position. The rod box 218 is substantially similar to the rod box 118 described above.
[0059] The rod box 218 is attached to the frame 106 with a pair of arms 230 a , 230 b . The arm 230 a is substantially similar to arm 130 a described above, and arm 230 b is similar to arm 130 b . Like arm 130 b , arm 230 b includes a stowed pocket 254 and an operational pocket 256 . The pockets 254 , 256 are configured to interface with a movable lever 258 that is movably secured to the rod box 218 . The arm 230 b also includes a stowed hard stop 257 and an operational hard stop 259 that aid in retaining the rod box 218 in either the stowed or operational position.
[0060] The movable lever 258 is positioned within a lever channel 260 that is defined by a bracket 261 that is attached to the rod box 218 . The lever 258 is spring loaded by a spring 264 attached to the lever 258 and the bracket 261 and biased in a downward direction toward the arm 230 b.
[0061] As shown in FIG. 22 , like the rod box 118 , when the rod box 218 is in the stowed position, the lever 258 is positioned within the stowed pocket 254 of the arm 230 b . In the depicted embodiment, the bracket 261 of the rod box 218 is also in contact with the stowed hard stop 257 of the arm 230 b . The stowed hard stop 257 helps prevent the rod box 218 from over-rotating while also removing excess force on the lever 258 when the rod box 218 is the stowed position. In some examples, the lever 258 can be loosely positioned within the stowed pocket 254 when in the stowed position while the weight of the rod box rests, via the bracket 261 , on the stowed hard stop 257 . In such an example, by positioning the lever 258 in the stowed pocket 254 , the rod box 218 is prevented from rotating back in a direction toward the operational position. However, in regular use, the weight of the rod box 218 is supported by the stowed hard stop 257 and the bracket 261 , thereby allowing the user to easily manipulate the lever 258 in an upward and downward motion without having to overcome excessive friction between the stowed pocket 254 and the lever 258 . In some examples, the stowed hard stop 257 can be lined with a bumper material, such as a rubberized material.
[0062] When moved to the operational position, as shown in FIG. 23 , the lever 258 is moved in an upward direction by the operator and then positioned within the operational pocket 256 of the arm 230 b . Similar to the stowed hard stop 257 described above, the operational hard stop 259 is configured to interface with the bracket 261 so as to support the weight of the rod box 218 in the operational position and to prevent the rod box 218 from over rotating past the operational position. Further, like the stowed pocket 254 , the lever 258 can be loosely positioned within the operational pocket 256 so as to prevent the rod box 218 from rotating back in a direction toward the stowed position. In some examples, the operational hard stop 259 can be lined with a bumper material, such a rubberized material.
[0063] The various embodiments described above are provided by way of illustration only and should not be construed to limit the claims attached hereto. Those skilled in the art will readily recognize various modifications and changes that may be made without following the example embodiments and applications illustrated and described herein, and without departing from the true spirit and scope of the following claims. | A horizontal directional drilling (HDD) machine that includes a rod box that has a large capacity, which allows the HDD machine to operate continuously for longer periods of time. The rod box has an upper end and a lower end and is pivotally connected to a frame of the HDD machine at a pivot axis positioned adjacent the lower end of the rod box. The rod box is pivotally movable between a stowed position and an operational position. The rod box obstructs movement of a drill head of the HDD machine when in the stowed position and is laterally offset from the drill head when in the operational position so as to not interfere with movement of the drill head. The rod box is tapered such that a width is larger adjacent the upper end of the rod box as compared to the lower end of the rod box. | 4 |
BACKGROUND OF THE INVENTION
The present invention is concerned with the vacuum annealing of worked reactive metal based articles. It is especially concerned with the use of induction heating in vacuum alpha annealing of cold pilgered zirconium base tubing.
Zircaloy-2 and Zircaloy-4 are commercial alloys, whose main usage is in water reactors such as boiling water (BWR), pressurized water (PWR) and heavy water (HWR) nuclear reactors. Those alloys were selected based on their nuclear properties, mechanical properties and high temperature aqueous corrosion resistance.
The history of the development of Zircaloy-2 and 4 is summarized in: Kass "The Development of the Zircaloys" published in ASTM Special Technical Publication No. 368 (1964) pp. 3-27, and Rickover et al. "History of the Development of Zirconium Alloys for use in Nuclear Reactors", NR: D: 1975. Also of interest with respect to Zircaloy development are U.S. Pat. Nos. 2,772,964; 3,097,094 and 3,148,055.
The commercial reactor grade Zircaloy-2 alloy is an alloy of zirconium comprising about 1.2 to 1.7 weight percent tin, about 0.07 to 0.20 weight percent iron, about 0.05 to 0.15 weight percent chromium and about 0.03 to 0.08 weight percent nickel. The commercial reactor grade Zircaloy-4 allow is an alloy of zirconium comprising 1.2 to 1.7 weight percent tin, about 0.18 to 0.24 weight percent iron, and about 0.07 to 0.13 weight percent chromium. Most reactor grade chemistry specifications for Zircaloy-2 and 4 conform essentially with the requirements published in ASTM B350-80 (for alloy UNS No. R60802 and R60804, respectively). In addition to these requirements the oxygen content for these alloys is typically required to be between 900 and 1600 ppm, but more typically is about 1200±200 ppm for fuel cladding applications. Variations of these alloys are also sometimes used. These variations include a low oxygen content alloy where high ductility is needed (e.g. thin strip for grid applications). Zircaloy alloys having small but finite additions of silicon and/or carbon are also commercially utilized.
It has been a common practice to manufacture Zircaloy (i.e. Zircaloy-2 and 4) cladding tubes by a fabrication process involving: hot working an ingot to an intermediate size billet or log; beta solution treating the billet; machining a hollow billet; high temperature alpha extruding the hollow billet to a hollow cylindrical extrusion; and then reducing the extrusion to substantially final size cladding through a number of cold pilger reduction passes (typically 2 to 5 passes with about 50 to about 85% reduction per pass), having an alpha recrystallization anneal prior to each pass. The cold worked, substantially final size cladding is then final alpha annealed. This final anneal may be a stress relief anneal, partial recrystallization anneal or full recrystallization anneal. The type of final anneal provided is selected based on the designer's specifications for the mechanical properties of the fuel cladding. Examples of these processes are described in detail in WAPD-TM-869 dated 11/79 and WAPD-TM-1289 dated 1/81. Some of the characteristics of Zircaloy fuel cladding tubes are described in Rose et al. "Quality Costs of Zircaloy Cladding Tubes" (Nuclear Fuel Performance published by the British Nuclear Energy Society (1973), pp. 78.1-78.4).
In the foregoing conventional methods of tubing fabrication the alpha recrystallization anneals performed between cold pilger passes and the final alpha anneal have been typically performed in large vacuum furnaces in which a large lot of intermediate or final size tubing could be annealed together. Typically the temperatures employed for these batch vacuum anneals of cold pilgered Zircaloy tubing have been as follows: about 450° to about 500° C. for stress relief annealing without significant recrystallization; about 500° C. to about 530° C. for partial recrystallization annealing; and about 530° C. to about 760° C. (however, on occasion alpha, full recrystallization anneals as high as about 790° C. have been performed) for full alpha recrystallization annealing. These temperatures may vary somewhat with the degree of cold work and the exact composition of the Zircaloy being treated. During the foregoing batch vacuum alpha anneals it is typically desired that the entire furnace load be at the selected temperatures for about one to about 4 hours, or more, after which the annealed tubes are vacuum or argon cooled.
The nature of the foregoing batch vacuum alpha anneals creates a problem which has not been adequately addresed by the prior art. This problem relates to the poor heat transfer conditions inherent in these batch vacuum annealing procedures which may cause the outer tubes in a large bundle to reach the selected annealing temperature within about an hour or two, while tubes located in the center of the bundle, after 7 to 10 hours (at a time when the anneal should be complete and cooling begun) have either not reached temperature, are just reaching temperature, or have been at temperature for half an hour or less. These differences in the actual annealing cycle that individual tubes within a lot experience can create a significant variation in the tube-to-tube properties of the resulting fuel cladding tubes. This variability in properties is most significant for tubes receiving a stress relief anneal for a partial recrystallization anneal, and is expected to be reduced by using a full recrystallization anneal. Where the fuel cladding design requires the properties of a stress relieved or partially recrystallized microstructure, a full recrystallization final anneal is not a viable option. In these cases extending the vacuum annealing cycle is one option that has been proposed, but is expensive in that it adds time and energy to an already long heat treatment which may already be taking on the order of 16 hours from the start of heating of the tube load to the completion of cooling.
Additional examples of the conventional Zircaloy tubing fabrication techniques, as well as variations thereon, are described in the following documents: "Properties of Zircaloy-4 Tubing" WAPD-TM-585; Edstrom et al. U.S. Pat. No. 3,487,675; Matinlassi U.S. Pat. No. 4,233,834; Naylor U.S. Pat. No. 4,090,386; Hofvenstam et al. U.S. Pat. No. 3,865,635; Andersson et al. "Beta Quenching of Zircaloy Cladding Tubes in Intermediate or Final Size," Zirconium in the Nuclear Industry: Fifth Conference, ASTM STP754 (1982) pp. 75-95.; McDonald et al. U.S. patent application Ser. No. 571,122 (a continuation of Ser. No. 343,787, filed Jan. 29, 1982 now abandoned and assigned to the Westinghouse Electric Company); Sabol et al. U.S. patent application Ser. No. 571,123 (a continuation of Ser. No. 343,788, filed Jan. 29, 1982, now abandoned and assigned to the Westinghouse Electric Corporation); Armijo et al. U.S. Pat. No. 4,372,817; Rosenbaum et al. U.S. Pat. No. 4,390,497; Vesterlund et al. U.S. Pat. No. 4,450,016; Vesterlund U.S. Pat. No. 4,450,020; and Vesterlund French Patent Application Publication No. 2,509,510 published Jan. 14, 1983.
SUMMARY OF THE INVENTION
In accordance with our invention, the prior art problems relating to nonuniform heating in batch vacuum furnaces can be substantially alleviated by heating the bundle of zirconium alloy tubes with an induction coil as they are moved from the cold zone to the hot zone of the vacuum furnace. In this manner the center of the bundle will have reached a temperature of between about 500° F. and the desired annealing temperature as the bundle enters the hot zone. Thusly, time for heating will be significantly reduced and tubes at the center and the periphery of the bundle will receive substantially the same time-temperature cycling during the annealing heat treatment.
These and other aspects of the present invention will become more apparent upon review of the drawings, briefly described below, in conjunction with the detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically shows the outline of an embodiment of vacuum furnace to be utilized in accordance with the present invention.
FIG. 2 shows an embodiment of a process in accordance with the present invention.
FIG. 3 shows a transverse cross-section through a tube bundle and the cold zone of the furnace shown in FIGS. 1 and 2 as the tube bundle is scanned by an induction coil in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with our invention, a hot wall vacuum furnace 1 is shown in FIG. 1. The furnace includes two cold zones 3 and a hot zone 5. Bundles of tubes may be placed in the furnace or retrieved from the furnace through either cold zone 3. Located near the end of one or both cold zones 3 closest to hot zone 5 is a large induction coil 7 having an inside diameter sufficient to allow a bundle of tubes, and the basket holding the tubes, to pass through the coil as a unit. This is more clearly shown in FIGS. 2 and 3. The hot zone includes a vacuum chamber 8 which is surrounded by electrical resistance heating elements and thermal insulation 10.
As shown in FIGS. 2 and 3, in accordance with our invention, a basket 21 holding cold pilgered Zircaloy tubes 23 is first pushed into one of the cold zones 3. The tubes are arranged in close packed arrangement as shown in FIG. 3 and fill the basket 21. The basket 21 is preferably long enough to hold two bundles of tubes in end to relation to each other. Each bundle may contain on the order of 600 tubes each having a nominal diameter of about 3/8 inch, for example, and a thin wall thickness typical of nuclear fuel cladding. The tubes have a length in excess of about 10 feet and are preferably either Zircaloy-2 or Zircaloy-4. The cold zone 3 containing the basket of tubes is then sealed and evacuated. The hot zone 5 is maintained at a temperature between about 820° and about 1450° F., and more preferably about 870° to about 1250° F. The exact temperature selected is determined by whether a stress relieved, partially recrystallized, or fully recrystallized microstructure is desired. After evacuation is complete and the hot zone is at the desired temperature a gate value between the hot and cold zones is opened and the basket 21 of tubes 23 is pushed through the energized induction coil 7. As the basket of tubes passes through the induction coil the tubes are inductively heated such that the entire cross-section of the bundle is heated to as near the desired annealing temperature as possible without exceeding the desired annealing temperature by more than 50° F. In practice, it is preferred that the central tube 23C or tubes, in the bundle attain at least 500° F. as they exit the induction coil 7, while the peripheral tubes 23P in the bundle are at a higher temperature which is still less than 50° F. above the desired annealing temperature. Preferably the temperature of the peripheral tubes does not exceed the desired annealing temperature.
As the tubes move through the coils 7 the hot end of the tubes moves into the hot zone 5. When the entire tube bundle has passed through the energized coil and is in the hot zone 5 of the furnace 1 the gate valve between the hot zone and cold zone is closed and power to the coil is turned off.
Since the bundle has been preheated by the coil the heat up time in the hot zone is significantly reduced and the center tubes 23C come up to the hot zone temperature within 2 to 3 hours, or less. In this manner, the difference in soak time seen by the tubes on the periphery of the bundle compared to the tubes in the center of the bundle has been reduced compared to prior art vacuum annealing practice. Upon completion of the anneal the gate value to cold zone 3 is opened and the tube bundle and basket are moved into the evacuated cold zone to cool prior to removal from the furnace.
While the annealed tube bundle is cooling, a second tube bundle in the other cold zone is being moved through an energized coil 7 on that side of the furnace and then into the hot zone.
In this manner, the process can be alternately repeated from each side of the hot zone without the need to cool the hot zone.
In an alternative embodiment, the cold zone 3 into which the hot tubes are pushed for cooling, may be flooded with an inert gas, such as argon, to speed up cooling.
The preceding examples have clearly demonstrated the benefits obtainable through the practice of the present invention. Other embodiments of the invention will become more apparent to those skilled in the art from a consideration of the specification or actual practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the invention being indicated by the following claims. All of the documents previously cited herein are hereby incorporated by reference. | A method of more rapidly and uniformly heating bundles of zirconium alloy tubes in a vacuum annealing furnace utilizes an induction coil to preheat the entire bundle as it is being moved into the hot zone of the furnace. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to a process for preparing hydroxamic acids from their corresponding esters in both the solution and solid phase. More particularly, the present invention relates to a process in which the addition of cyanide ion provides a novel method for the formation of hydroxamic acids from esters.
BACKGROUND OF THE INVENTION
[0002] Hydroxamic acid analogs are important targets in medicinal chemisty because of their bidentate chelating interaction with the catalytic Zn 2+ in the active site of metalloproteinases. (Fingleton, B. Expert Opin. Ther. Targets (2003), 7(3), 385-397; Clendeninn, N. J.; Appelt, K., Eds. Hydroxamic acid matrix metalloproteinase inhibitors. Humana Press: Totowa, N.J., 2000; pp. 113-142.
[0003] The direct solution-phase hydroxyamination of esters is generally achieved by a two-step methods involving 1) the potassium salt of hydroxylamine followed by the addition of the ester in alcohol solvent, Hauser, C. R.; Renfrow, W. B. Org. Syn., Coll. Vol. 2 1943, 67-68, or 2) saponification of the ester followed by activation of the acid and quenching with an O-protected hydroxylamine analog, Burns, C. J. et al. Angew. Chem. Int. Ed. 1998, 37, 2848-2850; Mori, K., et al. Tetrahedron 1988, 44, 6013-6020. In special cases, the hydroxyamination of esters has been achieved via enzymatic methods Chen, S-T. et al. Bioorg. Med. Chem. Letters 1992, 2, 1685-1690, and, for more reactive esters, by treatment with excess hydroxylamine in alcohol solvent. Spengler, J., et al. Synthesis 1998, 1, 67-70.
[0004] The solid-phase synthesis of hydroxamic acids via the direct cleavage of an ester-linked substrate has been reported. Dankwardt, S. M. SYNLETT 1998, 7, 761; Dankwardt, S. M., et al. Bioorg. Med. Chem. Letters 2000, 10, 2513-2516. However, this method requires exposure of the esterified resin to concentrated aqueous hydroxylamine in THF over 2 days and is limited in scope because of irreproducibility. Zhang, W., et al. J. Comb. Chem. 2001, 3, 151-153; Thouin, E., et al. Tetrahedron Letters 2000 457-460. The issue with simply using a hydroxylamine resin is that important chemistries like the Mitsunobu reaction and alkylations are problematic because of the acidic NH group (pKa˜10).
[0005] Alternatives to address this include a method where ester libraries are made on-resin, cleaved and re-attached to a hydroxylamine resin then cleaved again, Salvino, J. M., et al. Bioorg. Med. Chem. Lett. 2000, 10, 1637-1640; and specialized resins, Barlaam, B. et al. Tetrahedron 1999, 55, 7221-7232; Mellor, S. L., et al. Tetrahedron Letters 1997, 38, 3311-3314; Floyd, C. D., et al. Tetrahedron Letters 1996, 37, 8045-8048; Ede, N. J., et al. Letters Pep. Sci. 1999, 6,157-163; Bauer, U, et al. Tetrahedron Letters 1997, 7233-7236, where the hydroxylamine-linking group is fully protected. Ngu, K., et al. J. Org. Chem. 1997, 62, 7088-7089.
[0006] Also reported in the literature is the formation of amides from the reaction of an ester with an amine in the presence of small amounts of cyanide ion (Hogberg, T., et al. J. Org. Chem. 1987, 52, 2033-2036).
SUMMARY OF THE INVENTION
[0007] The present invention provides a novel method for the formation of hydroxamic acids comprising reacting under suitable conditions an ester with hydroxylamine in the presence of cyanide anion. The present invention provides an efficient conversion of esters to hydroxamic acids for the preparation of multigram quantities of compounds, and a versatile method for the preparation of compounds on the solid phase.
BRIEF DESCRIPTION OF FIGURES
[0008] FIG. 1 depicts the effect of mole concentration of cyanide on the reaction profile for the conversion of an ester to its hydroxamic acid.
DETAILED DESCRIPTION OF THE INVENTION
[0009] The present method improves upon the existing methods known in the art for the formation of hydroxamic acids from esters by transiently activating an ester towards the N-acylation of hydroxylamine. The present invention also extends the use of cyanide anion beyond its role in the conversion of esters to amides to encompass hydroxylamine as a reagent for both the solution and solid phase synthesis of hydroxamic acids.
[0010] As shown in Scheme 1, an ester of Formula I, wherein R 1 is any organic side chain such that if the side chain includes sensitive functional groups, they are appropriately protected, and R 2 is C 1-6 alkyl, preferably methyl, ethyl, or propyl.
[0011] Suitable conditions under which R 1 may be reacted with aqueous hydroxylamine, preferably from about 20 to about 80% aqueous hydroxylamine, include
in a protic solvent, preferably a C 1-6 alcoholic solvent most preferably C 1-4 such as methanol or ethanol, in which a cosolvent is optionally present, such as tetrahydrofuran, dimethylformamide, or halogen-containing hydrocarbons such as dichloromethane, chloroform and the like; in the presence of from about 5 to about 50 mole percent, preferably from about 20 to about 40 mole percent, of a cyanide salt such as potassium cyanide, sodium cyanide, or the like; at a temperature from about 0 to about 10° C., preferably at about 25° C.; to form a hydroxamic acid of Formula II.
[0017] An aspect of the present invention relates to the adaptation of the reaction to the solid phase chemisty described herein, wherein R 2a is a hydroxy-substituted resin that is activated to form ester linkages of Formula III, such as Wang resin, hydroxymethylbenzamide (HMBA-AM), HMBA-PGEG A resin, NOVASYN®TG HMBA resin, or hydroxymethylpolystyrene resin, preferably HMBA-AM.
[0018] Suitable conditions under which R 2a may be reacted with aqueous hydroxylamine, preferably from about 20 to about 80% aqueous hydroxylamine, include
in an organic solvent such as methanol, N,N-dimethylformamide (DMF), or tetrahydrofuran; or in a mixture of organic solvents such as DMF:methanol, THF:methanol, or DMF:methanol:THF; in the presence of from about 5 to about 50 mole percent, preferably from about 20 to about 40 mole percent, of a cyanide salt such as potassium cyanide, sodium cyanide, or the like; at a temperature from about 0 to about 100° C., preferably at about 25° C.; to form a hydroxamic acid of Formula IV, as shown in Scheme 2.
[0024] One skilled in the art will recognize that although the instant process is suitable for forming any hydroxamic acid, esters of formula I and formula III containing additional reactive functional groups may need to be protected using reagents and methods known to those skilled in the art. See Green, T. W., Wuts, P. G. M, Protective Groups in Organic Synthesis (2 nd Edition, 1991).
[0025] Reactions of the present invention may be monitored using a number of analytical methods familiar to one skilled in the art. It should be recognized that rates of reactions may be dependent upon variables such as reaction concentration, solvent, temperature, and pressure.
[0026] Those of ordinary skill in the art will recognize that reasonable variations in reagents, starting materials, concentrations and reaction conditions can be used without departing from the scope of the present invention. The following non-limiting examples are provided to further illustrate the present invention.
SPECIFIC EXAMPLES
[0027] All 1 H NMR were recorded on a Bruker 300 MHz spectrometer. Low resolution mass spectra were obtained on an Agilent 1100 Series LC/MSD. Elemental analyses were performed by Robertson Microlit Laboratories (Madison, N.J.). The analytical HPLC utilized in the time course experiments was a Hewlett Packard Series 1050 with a Phenomenex C-18 column (30×4.6 mm, 3 μM). The mobile phase for the HPLC analyses was a gradient of water/acetonitrile with a 0.05% TFA additive.
[0028] The following examples describe the invention in greater detail and are intended to illustrate the invention, but not to limit it.
[0029] Preparative Scale Solution Phase Procedures
Example 1
[0030] N-Hydroxy-2-phenylacetamide. To methyl phenylacetate (0.288 mL, 2.0 mmol) in THF: MeOH: 50% aqueous NH 2 OH (1:1:0.5, 2.5 mL) was added KCN (5 mg, 0.08 mmol, 4 mol %) and the mixture was stirred at ambient temperature. After 2 h the reaction was complete by HPLC. To the mixture was added saturated aqueous citric acid (25 mL) followed by extraction with EtOAc (3×25 mL). The organic phase was isolated, dried (MgSO 4 ), filtered, and the filtrate was concentrated in vacuo to give a residue. The residue was purified by reverse phase HPLC (C-18, 5μ 100×30 mm column), eluting with a gradient of acetonitrile: water (0.05% TFA). Following lyophilization of the product fractions there was obtained pure N-hydroxy-2-phenylacetamide as a fluffy solid (0.234 g, 77% yield): LRMS (M+H) + : 152.1 m/z; 1 H NMR (DMSO-d 6 ) δ: 10.6(s, 1H), 8.81(s, 1H), 7.2(m, 5H), 3.26(s, 2H); Anal (C,H,N): % C: (calc) 63.56; (found) 63.63; % H: (calc.) 6.00; (found) 5.91; % N: (calc.) 9.27, (found) 9.04.
Example 2
[0031] N-Hydroxy-3-phenylpropionamide. To methyl 3-phenyl propionate (0.328 g, 2.0 mmol) in THF: MeOH: 50% aqueous NH 2 OH (1:1:0.5, 2.5 mL) was added KCN (5 mg, 0.08 mmol, 4 mol %)) and the mixture was stirred at ambient temperature. After 3 h the reaction was complete by HPLC and saturated aqueous citric acid was added (25 mL) followed by extraction with EtOAc (3×25 mL). The organic phase was isolated, dried (MgSO 4 ), filtered, and the filtrate was concentrated in vacuo to give a residue. The residue was purified by reverse phase HPLC (C-18, 5μ 100×30 mm column), eluting with a gradient of acetonitrile: water (0.05% TFA). Following lyophilization of the product fractions there was obtained pure N-hydroxy-3-phenylpropionamide (IIc) as a fluffy solid (0.220 g, 67% yield): LRMS (M+H) + : 166.0 m/z; 1 H NMR (DMSO-d 6 ) δ: 10.31(s, 1H), 8.68(br, 1H), 7.17(m, 5H), 2.79(t, 2H), 2.21(t, 2H); Anal (C,H,N): % C (calc) 65.44, (found) 65.38; % H (calc.) 6.71, (found) 6.61; % N (calc.) 8.48, (found) 8.08.
Example 3
Solution Phase Time Course Experiments: Effect of KCN on the Conversion of Esters to Hydroxamic Acids
[0032] Methyl 3-phenylpropionate to N-hydroxy-3-phenylpropionamide. Two batches of methyl 3-phenylpropionoate (0.10 g, 0.38 mmol) in 1:1 THF: MeOH (1 mL) were prepared. A portion of 50% aqueous NH 2 OH (0.25 mL) was added to each batch followed by the immediate addition of KCN (5 mg, 0.08 mmol, 20 mol %) to one reaction while the other was maintained as a control. The parallel reactions were stirred at ambient temperature and 0.025 mL aliquots of each reaction mixture were withdrawn and diluted with 0.2 mL of MeOH at time points of 1, 2, 4, 6 and 24 h. The aliquots were analyzed by reverse phase HPLC within 10 min of being diluted. The ratio of starting ester methyl 3-phenylpropionate to product hydroxamic acid IIc was determined by reverse phase HPLC/MS and 1 H NMR and also by HPLC retention times.
[0033] The effect of KCN as a promoter in the solution phase N-hydroxyamination of esters of Formula I was explored as described above. Reactions in which KCN was present (5 mg, 0.08 mmol, 20 mol %) were run in THF:MeOH with 50% aqueous hydroxylamine at room temperature (Table 1). In all cases, the addition of KCN accelerated the formation of the desired hydroxamic acid, product IIa-e. The conversion of methyl benzoate (Compound Ia, entry 1) to its corresponding hydroxamic acid is essentially complete after 24 h, while little of the corresponding hydroxamic acid Ia is formed in that same time in the absence of KCN. For entries 2, 3 and 4, almost all of the ester Compounds Ib-Id converted to their corresponding hydroxamic acid IIb-IId within 6 h in the presence of KCN, while considerable amounts of Ib-Id remain for the controls (where KCN is absent). In the case of Compound Ie (entry 5) the reaction is complete after 2 h with KCN while 60% of Ie is unchanged after 24 h in the absence of KCN. Trace amounts of the corresponding carboxylic acid are formed as a by-product in entries 2 and 3 L≦2%) with more substantial amounts of carboxylic acid formed for methyl benzoate (entry 1, 15%) and methyl mandelate (entry 4, 8%). No carboxylic acid was detected for the dihydroindole Ie (entry 5).
TABLE 1 Solution Phase Hydroxamic acid Formation from Esters with and without KCN additive Ratio of Ester I:Hydroxamic Acid II without Entry R 1 Time (h) KCN with KCN 1 1 2 4 6 24 100:0 100:0 99:1 97:3 95:5 86:14 76:24 56:44 43:57 4:96 b 2 1 2 4 6 24 94:6 89:11 78:22 65:35 48:52 c 21:79 9:91 1:99 0:100 c — 3 1 2 4 6 24 82:18 73:27 62:38 58:42 38:62 41:59 17:83 4:96 2:98 2:98 c 4 1 2 4 6 87:13 82:18 65:35 57:43 d 4:96 1:99 0:100 d — 5 2 24 90:10 60:40 0:100 — a Ratios were calculated from the integrated area for the ester or hydroxamic acid HPLC peaks divided by the total area for the ester and hydroxamic acid multiplied by 100. b Final product contains about 15% carboxylic acid. c Final product contains trace (<2%) carboxylic acid. d Final product contains about 8% carboxylic acid.
Example 4
Evaluation of KCN on Reaction Profile
[0034] To five batches of methyl 3-phenylpropionoate (0.10 g, 0.38 mmol) in 1:1 THF: MeOH (1 mL) was added 50% aqueous NH 2 OH (0.25 mL). To four of the reactions KCN was added immediately in the following amounts: 1.2 mg (5 mol %), 2.5 mg (10 mol %), 5 mg (20 mol %) and 10 mg (40 mol %). One reaction was reserved as the control. The parallel reactions were stirred at ambient temperature and 0.025 mL aliquots of each reaction mixture was withdrawn and diluted with 0.2 mL of MeOH at time points of 1, 2, 4, 6 and 24 h. The aliquots were analyzed by reverse phase HPLC (214 nM) within 10 min of being diluted. Results are reported in FIG. 1 .
[0000] FIG. 1 . Effect of Increasing KCN Mole Concentration on the Rate of Conversion of Methyl 3-phenylpropionate to N-Hydroxy-3-phenylpropionamide.
[0035] As evidenced in FIG. 1 , 20 mol % and 40 mol % of KCN proved to be the most efficient, while even relatively the low amounts of KCN additive, 5 mol % and 10 mol %, were better than the unassisted (0%) run. For synthetic scale reactions, smaller amounts of KCN were found to be the most convenient. The hydroxamic acids of methyl phenylacetate Ib and methyl 3-phenylpropionate Ic were prepared on a 2 mmol scale using a mixture of THF: MeOH: 50% aqueous NH 2 OH (1:1:0.5, 2.5 mL) with KCN (5 mg, 0.08 mmol, 4 mol %). A 77% yield of the hydroxamic acid Iib was obtained from Ib after 2 h at ambient temperature and a 67% yield of the hydroxamic acid IIc from Ic after 3 h at ambient temperature.
Example 5
Solid Phase Preparative Scale Procedure
[0036] Hydroxamic acid of N-(4-methoxyphenylsulfonyl)-DL-phenylalanine. To N-(4-methoxyphenylsulfonyl)-DL-phenylalanine bound to hydroxymethylbenzamide (HMBA-AM) resin supplied by Calbiochem-Novabiochem Bad Soden, Germany (0.20 g of modified resin with a loading of 1 mmol of compound to 1 g of resin, 0.20 mmol) in THF: MeOH: 50% aqueous NH 2 OH (1:1:0.4, 2.4 mL) was added KCN (5 mg, 0.08 mmol, 40 mol %). The reaction was shaken at ambient temperature for 4 h, then the resin was filtered, washed with MeOH and the solution was evaporated with a stream of Argon gas. The residue was purified by reverse phase HPLC (C-18, 5μ 100×30 mm column) by elution with a gradient of acetonitrile: water (0.05% TFA). Following lyophilization of the product fractions there was obtained the pure hydroxamic acid of N-(4-methoxyphenylsulfonyl)-DL-phenylalanine (0.040 g, 0.11 mmol, 57% yield): LRMS (M+H) + : 351.0 m/z; 1 H NMR (DMSO-d 6 ) δ: 10.5(s, 1H), 8.80(br, 1H), 8.00(d, 1H), 7.47(d, 2H), 7.15(m, 3H), 7.05(m, 2H), 6.89(d, 2H), 3.78(s, 3H), 3.69(dd, 1H), 2.76(dd, 1H), 2.52(dd, 1H); Anal (C,H,N): % C: (calc.) 54.84, (found) 54.56; % H: (calc.) 5.18; (found) 4.88; % N: (calc.) 7.99, (found) 7.59.
Example 6
Solid Phase Preparative Scale Procedure
[0037] To explore the effectiveness of cyanide in the assistance of hydroxylamine mediated cleavage for solid phase library synthesis, hydroxymethylbenzamide (HMBA-AM) resin was chosen for the well-established compatibility between the ester linkage and Fmoc- and Boc-chemistry, and its stability towards Mitsunobu and reductive amination conditions. A solid phase library of DL-phenylalanine and several constrained analogs (AAa-c, Scheme 3) was prepared on the HMBA resin by the esterification of the Fmoc protected DL-aminoacids using standard DCC coupling conditions at room temperature overnight. The resin-bound Fmoc aminoacids BBa-c were deprotected with piperidine-DMF (1:4) and sulfonated with 4-methoxybenzenesulfonyl chloride to give Compounds IIIa-c. In this instance, the optimal reaction conditions for cleavage from the resin of the sulfonamide esters to yield the free hydroxamic acids (IVa-c, Table 2) were 5: 5:2 THF: MeOH: 50% aqueous NH 2 OH and 5 mg (0.08 mmol, 40 to 80 mol %) of KCN for 100 to 200 mg of loaded resin.
[0038] The importance of KCN additive using these conditions was assessed with this series of analogs by following the time-dependant cleavage of the substrates from the solid support by hydroxylamine in parallel experiments with and without KCN (Table 2). In the case of entries 1 and 2, KCN assisted cleavage to the hydroxamic acid is complete after 2 hours, while in the unassisted parallel experiments, up to 20 h or more for entries 1 and 2 are required. For entry 3, the KCN assisted experiment is complete after 2 hours while the unassisted cleavage from the resin to the hydroxamic acid is complete in 4 hours. It was important to follow these reactions carefully and work up them upon completion. Extended exposure to the hydroxylamine solution appeared to result in decomposition of the product.
Scheme 3. Preparation of the Solid Phase Library.
[0039] To demonstrate the utility of this procedure on a synthetic scale, 200 mg of the resin IIIa (0.2 mmol of compound based on a loading capacity of 1 mmol of compound per 1 g of HMBA-AM resin) was treated with a mixture of THF: MeOH: 50% aqueous NH 2 OH (1:1:0.4, 2.4 mL) and KCN (5 mg, 40 mol %) to give a 57% yield of hydroxamic acid IVa, based upon the presumed resin loading.
Example 7
Procedure for Solid Phase Resin Cleavage Time Course Experiments
Cleavage of N-(4-methoxyphenylsulphonyl)-DL-phenylalanine Modified HMBA-AM Resin (IIIa) to the Hydroxamic Acid IVa (Entry 1).
[0000] Stock Solution Preparation
[0040] Indan-1-ol (33 mg) was dissolved with a mixture of THF (5 mL): MeOH (5 mL): NH 4 OH (1 mL, 50% aqueous solution).
Resin Cleavage
[0041] THF (0.3 mL) and the stock solution (1 mL) prepared above were added to resin IIIa (100 mg, estimated at 0.1 mmol based upon theoretical resin loading) and the reaction was shaken. For the reaction with KCN, 5 mg of KCN (0.08 mmol, 80 mol %) was added immediately while, for the control, no KCN was added. At time points of 0.5, 1, 2, 4, 6 and 24 h an aliquot (0.05 mL) of the reaction was removed by syringe and immediately diluted with MeOH (0.20 mL). These samples were analyzed by HPLC within 10 min of sampling. The absorbance of the 1-indanol peak and the product IVa were recorded for each time point. For details on product peak identification and the data used to estimate the percent conversion to product see the Supplemental Material section.
TABLE 2 Solid Phase Reaction of Hydroxylamine with Esters of HMBA-AM Resin IIIa-c with and without KCN additive. % Conversion a to IV without with Entry Products Iva-c Time (h) KCN KCN 1 0.5 1 2 4 6 20 1.5 3 5.8 11.9 16 28 58 83 100 ——— 2 0.5 1 2 4 20 6.5 12 16 45 100 68 100 ——— 3 0.5 1 2 4 20 18 34 56 100 — 85 85 100 —— a Determination of ‘% Conversion’: The HPLC peak areas of products IVa-c were normalized to the peak area of an internal standard (1-indanol). Complete cleavage of the product was apparent when the normalized peak areas for IVa-c were observed to increase no further at subsequent time points. Percentages of conversion were all calculated relative to time point at which complete cleavage was observed. b In these experiments 5 mg (0.08 mmol, 80 mol %) of KCN was used for 100 mg of resin. | The present invention provides a novel method for the formation of hydroxamic acids comprising reacting under suitable conditions an ester with hydroxylamine in the presence of cyanide anion. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to secondary, rechargeable batteries, particularly such batteries which are constructed of layered, polymeric composition electrode and electrolyte elements laminated with electrically-conductive collector members, typically metallic foils. More particularly, the invention relates to such batteries comprising reticulate collector foils and provides a means for reducing the internal electrical resistance factor of such batteries which may, in part, be attributable to insulating metallic oxides formed on the surface of such collector foils, as well as the insulating effect of electrolyte solution wetting the electrode/collector foil interface.
Typical laminated polymeric composition battery structures with which the present invention is useful are described, for example, in U.S. Pat. Nos. 5,460,904 and 5,478,668. Such a battery comprises respective positive and negative polymeric matrix electrode composition layers of lithium intercalation compound and carbon which are laminated together and to metal foil current collector elements that provide the primary terminals for electrical connections.
As is known in the industry, the individual electrical resistance of each member of a battery structure contributes to an overall internal battery resistance which represents a nonproductive load and energy drain in any utilization circuit, particularly one which includes an external low impedance device. The power dissipated in overcoming such internal resistance not only detracts directly from the efficiency of a battery, it may further generate within the battery a level of heat which has a deleterious effect on not only the operation of the battery, but also on the integrity of the battery members, viz., the electrodes and electrolyte. Such effects are particularly felt by polymeric members of the noted laminated lithium ion rechargeable batteries.
A significant source of electrical resistance has been observed in the oxide which readily forms on the surface of the current collector foils, particularly aluminum, preferably employed with the polymer matrix lithium intercalation compound and carbon electrode compositions of battery cells such as described in the above-noted patents. Also contributing to the resistance in these cells has been the introduction of activating electrolyte solution which results in a swelling and expansion of the electrode members and intrusion of the solution between the electrode and collector surfaces, thereby interfering with the firm physical contact which ensures good electrical conductivity through these members.
The present invention provides an effective means of substantially eliminating the formation of insulating metal oxides on the collector elements, as well as of maintaining the integrity of a strong physical, electrically-conductive bond between the electrode and collector members, and thereby dramatically reducing the internal resistance of the Li-ion intercalation battery cells which are gaining favor in the industry.
SUMMARY OF THE INVENTION
In the implementation of the present invention, metal collector elements, typically of copper and aluminum foil and preferably in the form of open-mesh grids, are surface-treated with solvent and etching solution to remove processing oils and metallic oxides formed during manufacture. Thereafter, the collector foil surfaces are coated with a protective, metal-adherent, non-swelling polymeric composition comprising a homogeneously dispersed electrically-conductive material, such as carbon black, which serves to maintain the electrical conductivity between the coated collector member and its associated polymer-based electrode.
The polymer of the coating composition may be any material which is substantially insoluble in and preferably not wetted or swollen by the solvents, such as ethers, esters, or alcohols, used to extract the plasticizer, e.g., DBP, from the battery cell electrode and separator members, and the lithium salt solvents, such as the cyclic and acyclic carbonates, comprising activating electrolyte solutions. Polyolefin-based compositions, such as poly (ethylene-co-acrylic acid) copolymers serve well in this role. Such a selected polymer matrix not only provides a strongly-adherent protective film which deters subsequent oxidation, but also resists degradation of conductive continuity upon contact by subsequently-applied processing solvents and electrolyte solutions.
BRIEF DESCRIPTION OF THE DRAWING
The present invention will be described with reference to the accompanying drawing of which:
FIG. 1 is a perspective view of a representative section of a typical polymeric laminated battery structure;
FIG. 2 is a plan view of a section of a current collector grid member used in the battery structure of FIG. 1;
FIG. 3 is a cut-away elevational view of the current collector member section of FIG. 2 taken along line 4--4 showing the protective collector coating of the present invention;
FIG. 4 is a representation, in elevational section, of a typical polymeric laminated battery structure showing variations in disposition of the coated collector member within the structure; and
FIG. 5 presents comparative charge/discharge cycle traces of Li-ion cells comprising collector members with and without treatment according to the present invention.
DESCRIPTION OF THE INVENTION
The structure of a representative polymer-based Li-ion battery may be seen in the model of FIG. 1 as comprising a unitary laminate of a positive electrode composition layer 13 with its associated current collector member 12, an intermediate separator/electrolyte layer 14, and a negative electrode composition layer 15 with its associated current collector member 16. When initially assembled for lamination, the structure components typically include: as electrode 13, a 300 μm thick film of 56 parts by weight of a LiMn 2 O 4 intercalation compound and 6 parts of carbon black intimately dispersed in a binder matrix of 16 parts of an 88:12 vinylidene fluoride:hexafluoropropylene (PVdF:HFP) copolymer plasticized with 16 parts of dibutylphthalate (DBP); as separator 14, an 85 μm thick film of 20 parts of colloidal silica intimately dispersed in 30 parts of the copolymer plasticized with 50 parts of DBP; and as electrode 15, a 200 μm thick film of 56 parts of microbead coke and 3 parts of carbon black intimately dispersed in 15 parts of the copolymer plasticized with 23 parts of DBP.
Since, as described in the above-noted patents, the post-lamination processing of the battery structure will include a solvent extraction of the DBP plasticizer from the polymer matrices, one or both, as depicted in FIG. 1, of copper collector foil 16 and aluminum collector foil 12 may be reticulate, for example in the form of a 50 μm thick expanded metal grid, such as the MicroGrid precision foil marketed by Delker Corporation, in order to provide suitable pathways for solvent penetration.
In representative examples of a preferred embodiment of the present invention, respective sections of copper and aluminum expanded foil grid 20 (FIG. 2) were coated with a conductive composition of commercial grade conductive battery carbon black, such as MMM Super P, dispersed in a commercially-available aqueous suspension of a copolymer of polyethylene with acrylic acid, e.g., Morton International Adcote primer 50C12. The resulting current collector material comprised, as depicted in FIG. 3, the metal grid substrate 23 encompassed in about a 1-5 μm thick layer of conductive composition 34.
EXAMPLE 1
A typical coating composition was prepared by dispersing in a ball mill for about 1 h at room temperature about 5 parts by weight of carbon black, about 100 parts of about a 12% copolymer suspension, and about 100 parts of ethanol. The dispersion was then thinned with about an equal part of ethanol to provide a convenient viscosity for dip- or spray-coating the grid substrate which ensured retention of the open areas 25 in the grid. Prior to spraying portions of grid substrates with the coating composition, oils and oxides were removed from the foil surfaces with an acetone rinse and, for the aluminum grid, about a 50 s dip in a 1N aqueous solution of KOH or NaOH, followed by water and acetone rinses and drying. The conductive coating composition was then applied, and the coated grid material was dried in air at room temperature. The amount of carbon has been found to be useful in a range of about 5-50% by weight of the dried coating, preferably about 30%.
As a measure of the improvement in the resistance achieved by this treatment according to the invention, pairs of 160 mm 2 sections of treated and untreated copper grid were laminated to respective portions of about 180 μm thick films of the above coke electrode composition to form simple test cells. These cells were then tested for transverse electrical resistance at various stages representative of the processing of an actual battery cell. As initially prepared, the comparative resistances of the treated:untreated collector cells were 0.26Ω:0.6Ω. After methanol extraction of the DBP plasticizer, the cells tested at 0.15Ω:0.5Ω. Finally, after the cells were immersed in 1M LiPF 6 /EC/DMC electrolyte solution to substantially saturate the electrode composition, the tests indicated resistances of 0.20Ω:6.0Ω. Similar test cells were prepared of aluminum grid and films of LiMn 2 O 4 electrode composition. The staged resistance tests of the treated: untreated cells yielded results of 1.0Ω:1.57Ω, 0.72Ω:0.65Ω, and 0.83Ω:14.0Ω.
EXAMPLE 2
The coated collector grid materials of Example 1 were assembled with previously-described electrode and separator members 13, 14, 15 to fabricate battery cell laminates, such as depicted at 10 and 40 (FIG. 4). Due to the high level of electrical conductivity exhibited by the coated collector members, they may be respectively situated at any desired location in the cell structure. For example, each collector member may be overlaid upon its respective electrode film or layer, as shown in FIG. 1, to be laminated with and, if in grid form, embedded to any desired depth in its associated electrode upon the application of fabrication heat and pressure. Alternatively, as depicted in FIG. 4, to achieve further improvement in the reduction of internal cell resistance a coated grid collector member 41 may be laminated between sections of electrode material 43 in order to be situated wholly within the electrode, or a grid collector member 49 may be assembled at the interface between its associated electrode 47 and separator member 45. In such latter embodiments, it is convenient to allow for an extended collector grid tab, as at 42 or 48, in order to provide an accessible cell terminal.
After lamination, a completed battery cell as represented in FIG. 1 was processed as described in the noted patents by immersion in methanol to extract substantially all the DBP plasticizer from the electrode and separator matrix compositions. Ready access of the extracting solvent to these members is ensured by the retained grid openings in at least one of the collector members. Subsequent activation of the cell, in the described manner, by immersion in an electrolyte solution of 1M LiPF 6 in an equipart mixture of ethylene carbonate (EC) and dimethyl carbonate (DMC) prepared the cell for charge/discharge cycling. The cell exhibited remarkably good internal resistance of about 50-150 mΩ/Ah capacity.
EXAMPLE 3
In a comparative example to quantify the efficacy of the collector coating compositions of the invention, a similar cell was prepared in the manner described in U.S. Pat. No. 5,470,357, that is, the collector grid elements were pretreated with a thin, post-heated prime coat of the PVdF:HFP electrode matrix polymer to enhance lamination adhesion between the electrode and collector members. After extraction and activation with electrolyte solution, the cell exhibited an internal resistance of about 600-2000 mΩ/Ah capacity. Apparently, the normally employed solvents and electrolyte solutions whose functionality depends upon their swelling and penetrating the electrode and separator copolymer matrices also penetrated the collector element primer coatings and degraded the electrical continuity between the electrodes and the collector foil surfaces and contributed to the increased internal resistance. These results indicate the advantage achieved from the use of the preferred collector coating composition polymers which are substantially inert to the cell-processing solvents.
Further indicative of the efficacy of the collector element treatment of the present invention are the comparative cycling traces of FIG. 5 which evidence the lesser degree of available charging, represented by less deintercalation of lithium ions, in the untreated sample prior to charging current cut-off at 4.5 V, as well as the lower level of productive voltage output under the same constant current load.
It is anticipated that numerous other implementations of the described manner of effecting improved internal cell resistance will occur to the skilled artisan, and such variants are nonetheless intended to be within the scope of the present invention as defined in the appended claims. | An electrically-conductive collector element (23) in a polymeric laminate lithium ion rechargeable battery is cleaned of surface oxides and coated with an adherent conductive polymer film (34) which is substantially inert to battery electrolyte components and prevents recurrent formation of insulative collector surface oxides, thereby maintaining effective electrode/collector electrical conductivity and significantly reducing internal battery resistance. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a Continuation-In-Part of U.S. Ser. No. 10/768,209, filed Jan. 30, 2004, now abandoned, and a Continuation-In-Part of U.S. Ser. No. 10/284,728, filed Oct. 31, 2002 now U.S. Pat. No. 7,166,368, which claims priority to Provisional Application Ser. No. 60/347,910, dated Nov. 7, 2001.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to electroluminescent complexes of platinum(II). It also relates to electronic devices in which the active layer includes an electroluminescent Pt(II) complex.
2. Description of the Related Art
Organic electronic devices that emit light, such as light-emitting diodes that make up displays, are present in many different kinds of electronic equipment. In all such devices, an organic light-emitting layer is sandwiched between two electrical contact layers. At least one of the electrical contact layers is light-transmitting so that light can pass through the electrical contact layer. The organic layer emits light through the light-transmitting electrical contact layer upon application of electricity across the electrical contact layers.
It is well known to use organic electroluminescent compounds as the active component in light-emitting diodes. Simple organic molecules such as anthracene, thiadiazole derivatives, and coumarin derivatives are known to show electroluminescence. Semiconductive conjugated polymers have also been used as electroluminescent components, as has been disclosed in, for example, Friend et al., U.S. Pat. No. 5,247,190, Heeger et al., U.S. Pat. No. 5,408,109, and Nakano et al., Published European Patent Application 443 861. Complexes of 8-hydroxyquinolate with trivalent metal ions, particularly aluminum, have been extensively used as electroluminescent components, as has been disclosed in, for example, Tang et al., U.S. Pat. No. 5,552,678.
Electroluminescent devices with an light-emitting layer of polymer doped with organometallic complexes of platinum have been disclosed by Burrows and Thompson in published PCT application WO 00/57676. Electroluminescent complexes of platinum and electronic devices made with them have been disclosed by LeCloux et al. in published PCT application WO 03/040257.
However, there is a continuing need for efficient electroluminescent compounds.
SUMMARY OF THE INVENTION
The present invention is directed to a metal complex having Formula I, Formula II, or Formula III:
Pt(L 1 ) 2 (I)
PtL 1 L 2 (II)
PtL 1 L 3 L 4 (III)
where:
in Formulae I, II, and III: L 1 has Formula IV:
wherein:
R 1 =H, R 4 , OR 4 , N(R 4 ) 2
R 2 =H, C n F 2n+1 , C n F 2n+1 SO 2 , COOR 4 , CN
R 3 =H, C n F 2n+1 , C n F 2n+1 SO 2 , COOR 4 , CN,
R 4 is the same or different at each occurrence and is H, alkyl, aryl, or adjacent R 4 groups can join together to form a 5- or 6-membered ring, and
n is an integer from 1 through 20;
in Formula II:
L 2 is a monoanionic bidentate ligand;
in Formula III:
L 3 is a monoanionic monodentate ligand; and L 4 is a nonionic monodentate ligand.
In another embodiment, the present invention is directed to an organic electronic device having at least one active layer comprising the above metal complex, or combinations of the above metal complexes.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of one example of a light-emitting device (LED).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The metal complexes of the invention have Formula I, Formula II, or Formula III, given above, and are referred to as cyclometallated complexes. The platinum is in the +2 oxidation state and is tetracoordinate. The complex in Formula I is a bis-cyclometallated complex. The complex in Formula II is a cyclometallated complex with an additional monoanionic bidentate ligand, L 2 . The complex in Formula III is a cyclometallated complex with two additional monodentate ligands, L 3 and L 4 . The cyclometallated complexes are neutral and non-ionic, and can be sublimed intact. Thin films of these materials obtained via vacuum deposition may exhibit good to excellent electroluminescent properties.
Ligand L 1 having Formula IV, shown above, is derived from a phenyl-pyridine parent compound. In one embodiment of Formula IV, R 2 and R 3 are independently selected from H, CF 3 , C 2 F 5 , n-C 3 F 7 , i-C 3 F 7 , C 4 F 9 , CF 3 SO 2 , COOR 14 and CN.
The parent ligand compounds, HL 1 , can generally be prepared by standard palladium-catalyzed Suzuki or Kumada cross-coupling of the corresponding heterocyclic aryl chloride with an organoboronic acid or organomagnesium reagent, as described in, for example, O. Lohse, P. Thevenin, E. Waldvogel Synlett , 1999, 45-48. This reaction is illustrated in Equation (1) below.
In one embodiment, ligand L 1 is selected from the following ligands in Table 1 below.
TABLE 1
Ligands Having Formula IV
Ligand
R 1
R 2
R 3
1-a
H
H
H
1-b
H
CF 3
H
1-c
H
COOMe
H
1-d
H
CN
H
1-e
CH 3
H
H
1-f
CH 3
CF 3
H
1-g
CH 3
COOMe
H
1-h
CH 3
CN
H
1-i
CH 3
H
H
1-j
t-butyl
H
H
1-k
OMe
CF 3
H
1-l
OMe
COOMe
H
1-m
OMe
CN
H
1-n
OMe
CF 3
CF 3
1-o
NMe 2
H
H
1-p
NMe 2
CF 3
H
1-q
NMe 2
COOMe
H
1-r
NMe 2
CN
H
1-s
NMe 2
CF 3 SO 2
H
1-t
NMe 2
C 2 F 5
H
1-u
NMe 2
CF(CF 3 ) 2
H
1-v
NMe 2
H
H
1-w
NPh 2
CF 3
H
1-x
NPh 2
COOMe
H
1-y
NPh 2
CN
H
In one embodiment, ligand L 1 is derived from parent compounds having Formula V, Formula VI, Formula VII, Formula VIII, and Formula IX below:
The L 2 ligand is a monoanionic bidentate ligand. In general these ligands have N, O, P, or S as coordinating atoms and form 5- or 6-membered rings when coordinated to the platinum. Suitable coordinating groups include amino, imino, amido, alkoxide, carboxylate, phosphino, thiolate, and the like. Examples of suitable parent compounds for these ligands include β-dicarbonyls (β-enolate ligands), and their N and S analogs; amino carboxylic acids (aminocarboxylate ligands); pyridine carboxylic acids (iminocarboxylate ligands); salicylic acid derivatives (salicylate ligands); hydroxyquinolines (hydroxyquinolinate ligands) and their S analogs; and diarylphosphinoalkanols (diarylphosphinoalkoxide ligands). In one embodiment, L 2 is selected from a β-enolate and a phosphino alkoxide.
The β-enolate ligands generally have the Formula X
where R 5 is the same or different at each occurrence. The R 5 groups can be hydrogen, halogen, substituted or unsubstituted alkyl, aryl, alkylaryl or heterocyclic groups. Adjacent R 5 and R 6 groups can be joined to form five- and six-membered rings, which can be substituted. In one embodiment, R 5 groups are selected from C n (H+F) 2n+1 , —C 6 H 5 , c-C 4 H 3 S, and c-C 4 H 3 O, where n is an integer from 1 through 20. The R 6 group can H, be substituted or unsubstituted alkyl, aryl, alkylaryl or heterocyclic groups, or fluorine.
Examples of suitable β-enolate ligands include the compounds listed below. The abbreviation for the β-enolate form is given below in brackets.
2,4-pentanedionate [acac] 1,3-diphenyl-1,3-propanedionate [DI] 2,2,6,6-tetramethyl-3,5-heptanedionate [TMH] 4,4,4-trifluoro-1-(2-thienyl)-1,3-butanedionate [TTFA] 7,7-dimethyl-1,1,1,2,2,3,3-heptafluoro-4,6-octanedionate [FOD] 1,1,1,3,5,5,5-heptafluoro-2,4-pentanedionate [F7acac] 1,1,1,5,5,5-hexaflouro-2,4-pentanedionate [F6acac] 1-phenyl-3-methyl-4-i-butyryl-pyrazolinonate [FMBP]
The β-dicarbonyl parent compounds, are generally available commercially. The parent compound 1,1,1,3,5,5,5-heptafluoro-2,4-pentanedione, CF 3 C(O)CFHC(O)CF 3 , can be prepared using a two-step synthesis, based on the reaction of perfluoropentene-2 with ammonia, followed by a hydrolysis step. This compound should be stored and reacted under anyhydrous conditions as it is susceptible to hydrolysis.
The hydroxyquinolinate ligands can be substituted with groups such as alkyl or alkoxy groups which may be partially or fully fluorinated. Examples of suitable hydroxyquinolinate ligands include (with abbreviation provided in brackets):
8-hydroxyquinolinate [8hq] 2-methyl-8-hydroxyquinolinate [Me-8hq] 10-hydroxybenzoquinolinate [10-hbq]
The parent hydroxyquinoline compounds are generally available commercially.
Phosphino alkoxide ligands generally have Formula XI, below:
where
R 7 can be the same or different at each occurrence and is selected from H and C n (H+F) 2n+1 , R 8 can be the same or different at each occurrence and is selected from C n (H+F) 2n+1 and C 6 (H+F) 5 , or C 6 H 5−b (R 9 ) b , R 9 =CF 3 , C 2 F 5 , n-C 3 F 7 , i-C 3 F 7 , C 4 F 9 , CF 3 SO 2 , and φ is 2 or 3; b is 0-5; and n is 1-20.
Examples of suitable phosphino alkoxide ligands include (with abbreviation provided in brackets):
3-(diphenylphosphino)-1-oxypropane [dppO] 1,1-bis(trifluoromethyl)-2-(diphenylphosphino)-ethoxide [tfmdpeO]
Some of the parent phosphino alkanol compounds are available commercially, or can be prepared using known procedures, such as, for example, the procedure reported for ffmdpeO in Inorg. Chem . 1985, v.24, p.3680.
In one embodiment, the phosphino alkoxide has Formula XII below:
In one embodiment, L 2 is a ligand coordinated through a carbon atom which is part of an aromatic group. The ligand can have Formula XIII:
Ar[—(CH 2 ) q —Y] p (XIII)
wherein Ar is an aromatic group, Y is a group having a heteroatom capable of coordinating to Pt, q is 0 or an integer from 1 through 20, p is an integer from 1 through 5, and further wherein one or more of the carbons in (CH 2 ) q can be replaced with a heteroatom and one or more of the hydrogens in (CH 2 ) q can be replaced with D or F.
In one embodiment of Formula XIII, Y is selected from N(R 10 ) 2 , OR 10 , SR 10 , and P(R 11 ) 2 , wherein R 10 is the same or different at each occurrence and is H, C n H 2n+1 or C n (H+F) 2n+1 and R 11 is the same or different at each occurrence and is selected from H, R 10 , Ar and substituted Ar.
In one embodiment of Formula XIII, Ar is phenyl, q is 1, Y is P(Ar) 2 , and p is 1 or 2.
The L 3 ligand is a monoanionic monodentate ligand. Such ligands include, but are not limited to, H − (“hydride”) and ligands having C, O or S as coordinating atoms. Coordinating groups include, but are not limited to alkoxide, carboxylate, thiocarboxylate, dithiocarboxylate, sulfonate, thiolate, carbamate, dithiocarbamate, thiocarbazone anions, sulfonamide anions, and the like. In some cases, ligands listed above as L′, such as β-enolates and phosphinoakoxides, can act as monodentate ligands. The monodentate ligand can also be a coordinating anion such as halide, nitrate, sulfate, hexahaloantimonate, and the like. These ligands are generally available commercially.
The L 4 ligand is a nonionic monodentate ligand, such as CO or phosphine. In one embodiment, L 4 is a monodentate phosphine ligand having Formula XIV
PAr 3 (XIV)
where Ar represents an aryl or heteroaryl group. The Ar group can be unsubstituted or substituted with alkyl, heteroalkyl, aryl, heteroaryl, halide, carboxyl, sulfoxyl, or amino groups. The L 4 phosphine ligands are generally available commercially.
In one embodiment, the complexes of the invention exhibit blue luminescence. In one embodiment, the complexes have photoluminescent and/or electroluminescent spectra which have a maximum at 500 nm or less. In one embodiment, the maximum is less than 480 nm.
Complexes of Formula I are generally prepared from metal chloride salts and an excess of the parent ligand compound HL 1 . This is illustrated in Equation (2) below.
Complexes of Formula II are generally prepared from metal chloride salts by first forming the bridged chloride dimer. This reaction is illustrated in Equation (3) below.
Complexes of Formula II are then formed by adding a salt of the parent ligand compound, such as NaL 2 , to the bridged chloride dimer. This reaction is illustrated using the sodium salt of a β-enolate ligand in Equation (4) below.
The salts of the parent ligand compounds can be made by any conventional methods, such as by the addition of sodium hydride to HL 2 in an inert solvent.
Complexes of Formula III are also generally prepared by first forming the bridged chloride dimer. To the dimer is then added the other two ligands. L 3 can be added as the silver salt, AgL 3 . L 4 is added as the neutral ligand. The reaction is illustrated in Equation (5) below.
Electronic Device
The present invention also relates to an electronic device comprising at least one layer positioned between two electrical contact layers, wherein the at least one photoactive layer of the device includes the complex of the invention. FIG. 1 is an illustrative example of an organic electronic device comprising a photoactive layer that comprises the present invention. Other device architectures would benefit from the present invention, as well and are numerous. In FIG. 1 , device 100 has an anode layer 110 and a cathode layer 150 and electroactive layers 120 , 130 and optionally 140 between the anode 110 and cathode 150 . Adjacent to the anode is a hole injection/transport layer 120 . Adjacent to the cathode is an optional layer 140 comprising an electron transport material. Between the hole injection/transport layer 120 and the cathode (or optional electron transport layer) is the photoactive layer 130 . Layers 120 , 130 , and 140 are individually and collectively referred to as the active layers.
Depending upon the application of the device 100 , the photoactive layer 130 can be a light-emitting layer that is activated by an applied voltage (such as in a light-emitting diode or light-emitting electrochemical cell), a layer of material that responds to radiant energy and generates a signal with or without an applied bias voltage (such as in a photodetector). Examples of photodetectors include photoconductive cells, photoresistors, photoswitches, phototransistors, and phototubes, and photovoltaic cells, as these terms are describe in Markus, John, Electronics and Nucleonics Dictionary , 470 and 476 (McGraw-Hill, Inc. 1966).
The complexes of the invention are particularly useful as the active material in the emitting layer of an OLED, or as electron transport material in layer 140 . Preferably the platinum complexes of the invention are used as the light-emitting material in diodes. When used in layer 130 , it has been found that the complexes of the invention do not need to be in a solid matrix diluent in order to be effective, althougth they may be. A layer that is greater than 20% by weight metal complex, based on the total weight of the layer, up to substantially 100% by weight metal complex, can be used as the emitting layer. By “substantially 100%” it is meant that the metal complex is the only material in the layer, with the possible exception of impurities or adventitious byproducts from the process to form the layer. Additional materials can be present in the emitting layer with the iridium compound. For example, a fluorescent dye may be present to alter the color of emission. A diluent may also be added and such diluent may be a charge transport material or an inert matrix. A diluent may comprise polymeric materials, small molecules or mixtures thereof. A diluent may act as a processing aid, may improve the physical or electrical properties of films containing the platinum compound, may decrease self-quenching in the platinum compounds, and/or may decrease the aggregation of the platinum compounds described herein. The diluent can comprise a polymeric material, small molecule or mixtures thereof. Non-limiting examples of such diluents include poly(N-vinyl carbazole) and polysilane. It can also be a small molecule, such as 4,4′-N,N′-dicarbazole biphenyl or tertiary aromatic amines. When a diluent is used, the metal complex is generally present in a small amount, usually less than 20% by weight, preferably less than 10% by weight, based on the total weight of the layer.
Examples of suitable conjugated polymers include polyarylenevinylenes, polyfluorenes, polyoxadiazoles, polyanilines, polythiophenes, polypyridines, polyphenylenes, copolymers thereof, and combinations thereof. The conjugated polymer can be a copolymer having non-conjugated portions of, for example, acrylic, methacrylic, or vinyl, monomeric units. In one embodiment, the diluent comprises homopolymers and copolymers of fluorene and substituted fluorenes.
In some cases the metal complexes of the invention may be present in more than one isomeric form, or mixtures of different complexes may be present. It will be understood that in the above discussion of OLEDs, the term “the metal complex” is intended to encompass mixtures of complexes and/or isomers.
The device generally also includes a support (not shown) which can be adjacent to the anode or the cathode. Most frequently, the support is adjacent the anode. The support can be flexible or rigid, organic or inorganic. Generally, glass or flexible organic films are used as a support. The anode 110 is an electrode that is particularly efficient for injecting or collecting positive charge carriers. The anode is preferably made of materials containing a metal, mixed metal, alloy, metal oxide or mixed-metal oxide. Suitable metals include the Group 11 metals, the metals in Groups 4, 5, and 6, and the Group 8-10 transition metals. If the anode is to be light-transmitting, mixed-metal oxides of Groups 12, 13 and 14 metals, such as indium-tin-oxide, are generally used. The anode 110 may also comprise an organic material such as polyaniline as described in “Flexible light-emitting diodes made from soluble conducting polymers,” Nature vol. 357, pp 477-479 (11 Jun. 1992).
The anode layer 110 is usually applied by a physical vapor deposition process or spin-cast process. The term “physical vapor deposition” refers to various deposition approaches carried out in vacuo. Thus, for example, physical vapor deposition includes all forms of sputtering, including ion beam sputtering, as well as all forms of vapor deposition such as e-beam evaporation and resistance evaporation. A specific form of physical vapor deposition which is useful is rf magnetron sputtering.
There is generally a hole transport layer 120 adjacent the anode. Examples of hole transport materials for layer 120 have been summarized for example, in Kirk-Othmer Encyclopedia of Chemical Technology, Fourth Edition, Vol. 18, p. 837-860, 1996, by Y. Wang. Both hole transporting molecules and polymers can be used. Commonly used hole transporting molecules, in addition to TPD and MPMP mentioned above, are: 1,1-bis[(di4-tolylamino) phenyl]cyclohexane (TAPC); N,N′-bis(4-methylphenyl)-N,N′-bis(4-ethylphenyl)-[1,1′-(3,3′-dimethyl)biphenyl]4,4′-diamine (ETPD); tetrakis-(3-methylphenyl)-N,N,N′,N′-2,5-phenylenediamine (PDA); a-phenyl-4-N,N-diphenylaminostyrene (TPS); p-(diethylamino)benzaldehyde diphenylhydrazone (DEH); triphenylamine (TPA); 1-phenyl-3-[p-(diethylamino)styryl]-5-[p-(diethylamino)phenyl] pyrazoline (PPR or DEASP); 1,2-trans-bis(9H-carbazol-9-yl)cyclobutane (DCZB); N, N, N′,N′-tetrakis(4-methylphenyl)-(1,1′-biphenyl)4,4′-diamine (TTB); and porphyrinic compounds, such as copper phthalocyanine. Commonly used hole transporting polymers are polyvinylcarbazole, (phenylmethyl)polysilane, poly(3,4-ethylendioxythiophene) (PEDOT), and polyaniline. It is also possible to obtain hole transporting polymers by doping hole transporting molecules such as those mentioned above into polymers such as polystyrene and polycarbonate.
Optional layer 140 can function both to facilitate electron transport, and also serve as a buffer layer or anti-quenching layer to prevent quenching reactions at layer interfaces. Preferably, this layer promotes electron mobility and reduces quenching reactions. Examples of electron transport materials for optional layer 140 include metal chelated oxinoid compounds, such as tris(8-hydroxyquinolato)aluminum (Alq 3 ); phenanthroline-based compounds, such as 2,9-dimethyl-4,7-diphenyl-1,10-phenanthroline (DDPA) or 4,7-diphenyl-1,10-phenanthroline (DPA), and azole compounds such as 2-(4-biphenylyl)-5-(4-t-butylphenyl)-1,3,4-oxadiazole (PBD) and 3-(4-biphenylyl)-4-phenyl-5-(4-t-butylphenyl)-1,2,4-triazole (TAZ).
The cathode 150 is an electrode that is particularly efficient for injecting or collecting electrons or negative charge carriers. The cathode can be any metal or nonmetal having a lower work function than the first electrical contact layer (in this case, an anode). Materials for the second electrical contact layer can be selected from alkali metals of Group 1 (e.g., Li, Cs), the Group 2 (alkaline earth) metals, the Group 12 metals, the lanthanides, and the actinides. Materials such as aluminum, indium, calcium, barium, samarium and magnesium, as well as combinations, can be used.
It is known to have other layers in organic electronic devices. For example, there can be a layer (not shown) between the conductive polymer layer 120 and the active layer 130 to facilitate positive charge transport and/or band-gap matching of the layers, or to function as a protective layer. Similarly, there can be additional layers (not shown) between the active layer 130 and the cathode layer 150 to facilitate negative charge transport and/or band-gap matching between the layers, or to function as a protective layer. Layers that are known in the art can be used. In addition, any of the above-described layers can be made of two or more layers. Alternatively, some or all of inorganic anode layer 110 , the conductive polymer layer 120 , the active layer 130 , and cathode layer 150 , may be surface treated to increase charge carrier transport efficiency. The choice of materials for each of the component layers is preferably determined by balancing the goals of providing a device with high device efficiency.
It is understood that each functional layer may be made up of more than one layer.
The device can be prepared by sequentially vapor depositing the individual layers on a suitable substrate. Substrates such as glass and polymeric films can be used. Conventional vapor deposition techniques can be used, such as thermal evaporation, chemical vapor deposition, and the like. Alternatively, the organic layers can be coated from solutions or dispersions in suitable solvents, using any conventional coating technique. In general, the different layers will have the following range of thicknesses: anode 110 , 500-5000 Å, preferably 1000-2000 Å; hole transport layer 120 , 50-2500 Å, preferably 200-2000 Å; light-emitting layer 130 , 10-1000 Å, preferably 100-800 Å; optional electron transport layer 140 , 50-1000Å, preferably 100-800 Å; cathode 150 , 200-10,000Å, preferably 300-5000 Å. The location of the electron-hole recombination zone in the device, and thus the emission spectrum of the device, is affected by the relative thickness of each layer. For examples, when an emitter, such as Alq 3 is used as the electron transport layer, the electron-hole recombination zone can be in the Alq 3 layer. The emission would then be that of Alq 3 , and not the desired sharp lanthanide emission. Thus the thickness of the electron-transport layer must be chosen so that the electron-hole recombination zone is in the light-emitting layer. The desired ratio of layer thicknesses will depend on the exact nature of the materials used.
It is understood that the efficiency of the devices of the invention made with metal complexes, can be further improved by optimizing the other layers in the device. For example, more efficient cathodes such as Ca, Ba, Mg/Ag, or LiF/Al can be used. Shaped substrates and novel hole transport materials that result in a reduction in operating voltage or increase quantum efficiency are also applicable. Additional layers can also be added to tailor the energy levels of the various layers and facilitate electroluminescence.
The complexes of the invention often are phosphorescent and photoluminescent and may be useful in other applications. For example, the complexes may be used as oxygen sensitive indicators, as phosphorescent indicators in bioassays, and as catalysts.
As used herein, the term “compound” is intended to mean an electrically uncharged substance made up of molecules that further consist of atoms, wherein the atoms cannot be separated by physical means. The term “ligand” is intended to mean a molecule, ion, or atom that is attached to the coordination sphere of a metallic ion. The letter “L” when used to designate a ligand having a nominal (−1) charge, is considered to be derived from the neutral parent compound, “HL”, by the loss of a hydrogen ion. The term “complex”, when used as a noun, is intended to mean a compound having at least one metallic ion and at least one ligand. The term “β-dicarbonyl” is intended to mean a neutral compound in which two ketone groups are present, separated by a CHR group. The term “β-enolate” is intended to mean the anionic form of the β-dicarbonyl in which the H from the CHR group between the two carbonyl groups has been abstracted. The term “group” is intended to mean a part of a compound, such as a substituent in an organic compound or a ligand in a complex. The phrase “adjacent to,” when used to refer to layers in a device, does not necessarily mean that one layer is immediately next to another layer. On the other hand, the phrase “adjacent R groups,” is used to refer to R groups that are next to each other in a chemical formula (i.e., R groups that are on atoms joined by a bond). The term “photoactive” refers to any material that exhibits electroluminescence and/or photosensitivity. In addition, the IUPAC numbering system is used throughout, where the groups from the Periodic Table are numbered from left to right as 1 through 18 (CRC Handbook of Chemistry and Physics, 81 st Edition, 2000). In the Formulae and Equations, the letters L, R and Y are used to designate atoms or groups which are defined within. All other letters are used to designate conventional atomic symbols. The term “(H+F)” is intended to mean all combinations of hydrogen and fluorine, including completely hydrogenated, partially fluorinated or perfluorinated substituents. By “emission maximum” is meant the wavelength, in nanometers, at which the maximum intensity of electroluminescence is obtained. Electroluminescence is generally measured in a diode structure, in which the material to be tested is sandwiched between two electrical contact layers and a voltage is applied. The light intensity and wavelength can be measured, for example, by a photodiode and a spectrograph, respectively.
As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
Also, use of the “a” or “an” are employed to describe elements and components of the invention. This is done merely for convenience and to give a general sense of the invention. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.
EXAMPLES
The following examples illustrate certain features and advantages of the present invention. They are intended to be illustrative of the invention, but not limiting. All percentages are mole percents, unless otherwise indicated.
Example 1
This example illustrates the preparation of parent ligand compound V.
Preparation of 2,4-difluoro-3-trifluoromethylbenzeneboronic acid
To a solution of 2.4 g of 2,6-difluoro-trifluoromethylbenzene in the mixture of 25 ml of dry ether and 25 ml of dry THF 7 ml of solution 2M butyl lithium in pentane was added dropwise at −70° C. The reaction mixture was stirred 15 min at −70° C. and 2 g of trimethylborate was added. The reaction was allowed to warm up to 25° C. and was diluted with 200 ml of 10% hydrochloric acid and extracted with ether (2×50 ml). The combined organic layers were washed with water (2×100 ml), dried over MgSO 4 and solvent was remover under vacuum at 50° C. to leave 3.4 g of crude boronic acid (containing ˜50% of THF), which was used for the next reaction without further purification. 1 H NMR (CDCl 3 ): 6.9 (2H, t), 7.9 (1H, q), 5.3 (2H, br s); 19 F NMR: −56.68 (3F, t), −106.0 (1F, m), −108.0 (1F, m).
Preparation of 2-(2,4-difluoro-3-trifluoromethylphenvl)-pyridine. Formula V.
To a solution of 10 g potassium carbonate in 100 ml of degassed water, the solution of 3.4 g 2,4-difluoro-3-trifluoromethylbenzeneboronic acid (50% purity, the rest THF) in 50 ml of monoglyme was added, followed by the addition of 3.5 g of 2-bromopyridine, 0.1 g of dicyclohexyl(biphenyl)phosphine, 0.05 g of palladium acetate. The reaction mixture was refluxed (90-95° C.) for 16 h. The reaction mixture was diluted with 500 ml of water, extracted with dichloromethane (3×50 ml), the organic layer was washed with water (1×300 ml), dried over MgSO 4 and solvent was removed under vacuum. Crude product (3.2 g) was dissolved in 50 ml of hexane and the solution was passed through a short plug of silicagel (Silicagel 60, EM Science). The column was washed with another 30 ml of hexane. From final solution hexane was removed under vacuum to leave 1.6 g of slightly yellow liquid, which based on NMR analysis was 2-(2,4-difluoro-3-trifluoromethylphenyl)-pyridine, containing 27% of 2-bromopyridine. The crude material was used for the next reaction without further purification.
Example 2
This example illustrates the preparation of a complex of the invention having Formula XV:
To 0.18 g platinum chloride and 0.1 g tetrapentylammonium chloride in 10 mL chlorobenzene was added 0.18 g of the parent ligand compound from Example 1. This was refluxed under nitrogen for 1 hour and then evaporated to dryness in a nitrogen stream. The residue was redissolved into 5 mL 2-ethoxyethanol to which was added 0.24 g di-t-butylacetylacetone (tetramethylheptanedione) and 180 mg sodium carbonate. This mixture was refluxed under nitrogen for 30 mins and then cooled. This was then evaporated to dryness in a nitrogen stream, extracted into methylene chloride, and filtered through silica to remove dark brown material. The solid was recrystallized from methanol/methylene chloride, resulting in a pale yellow solid which was bright blue green luminescent. Analysis by nmr indicated that the material had Formula XV. | The present invention is generally directed to electroluminescent Pt(II) complexes which have emission maxima across the visible spectrum, and devices that are made with the Pt(II) complexes. | 8 |
RELATED APPLICATIONS
[0001] This application claims the benefit of priority to Provisional Application No. 62/310,032, filed Mar. 18, 2016, which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] The disclosed embodiments concern systems and methods for beach erosion abatement. More specifically, the disclosed embodiments concern modular shell reefs emplaced within the surf zone to reduce scouring of a beach and the receding of the shoreline.
BACKGROUND
[0003] A beach protects the coast, normally not in contact with the ocean water, against the erosive forces of waves and currents. The coast, consisting of dunes, banks, bluffs, cliffs and similar features, is not normally in contact with the ocean. But the toe of the coast, where the coast meets the beach, may be exposed to the erosive forces of ocean waves during astronomical high tides or storm surges. The toe of the coast cannot generally withstand these erosive forces and can be scoured and sluiced away. This may undermine the coast, for example causing portions of dunes, banks, bluffs, or cliffs to collapse and leading to further erosion.
[0004] The beach is therefore the first line of defense in preventing erosion. Sand is naturally deposited on a beach cyclically in layers by the action of ocean currents, waves, and tides. These layers consist of various gradations of sand particles, clay and silt, including organic substances which add an element of cohesive strength. A natural beach generated through such deposition, with a naturally occurring elevation and gradient, can resist the scouring force of ocean waves and currents.
[0005] However, an artificial beach provides at most a temporary protective effect. Such beaches may be produced by spreading washed or de-watered sand. During the process of washing or watering, fines such as silts, clay and organic substances are flushed out. Consequently, unlike naturally deposited sand, this washed or de-watered sand lacks cohesion and will quickly be reclaimed by the ocean. Unless the washed or de-watered sand can be retained on the artificial beach, the expensive and environmentally disruptive process of mining or dredging sand, processing it, and dumping it on the artificial beach must be periodically repeated.
[0006] Armoring the coastline with revetments or similar barriers creates other problems. In part, these devices cut off the flow of sediment that nourishes other beaches. Furthermore, the swash and backwash of the incoming waves can lower the elevation of the beach, undermining and destabilizing the revetment. This may cause the revetment to fail, causing the eventual loss of the beach. Sand filled bags, tubes or containers that restrict the free movement of sand particles act as armor, similar to revetments with similar problems. The backwash can become trapped behind these barriers, causing unintended problems. Methods that armor the coastline may also be unsightly, creating opposition to these methods.
[0007] Present methods of erosion abatement are therefore expensive, environmentally disruptive, and ineffective. A need exists for improved erosion abatement techniques that retain the washed or de-watered sand on the beach for more cohesive deposition during cycles of natural beach accretion. Such techniques should also minimally interfere with recreational use of the beach, and preferably provide a beneficial environment for desirable sea life.
SUMMARY
[0008] The disclosed embodiments can include a sand-retaining shell module adapted for placement near a shoreline. This shell module can comprise two footers generally parallel to a longitudinal axis. These footers can include and outer face and an inner face. The shell module may further comprise a bridging member. The bridging member can connect the two footers, and can have a convex upper surface peaking at the longitudinal axis and extending downward on either side of the longitudinal axis to meet the outer face of each footer. The bridging member can also have a concave undersurface peaking at the longitudinal axis and extending downward on either side of the longitudinal axis to meet the inner face of each footer. The shell module, when viewed from above, may have a generally square or rectangular peripheral outline. In some embodiments, the shell module may comprise a unitary structure made with a mold.
[0009] In some embodiments, the shell module may have a first end and a second end, each generally orthogonal to the longitudinal axis. The first end can be formed with a projection and the second end can be formed with a complementary recess, enabling installation of adjacent shell modules in an interlocked configuration.
[0010] In some embodiments, the bridging member can be formed with a central portion aligned with the longitudinal axis and a perforated portion connecting the central portion and one of the two footers. The perforated portion may be formed with a plurality of slots extending from the upper surface to the undersurface of the bridging member, thereby facilitating passage of water and marine life through said module. The bridging member may reduce in thickness from at least one of the two footers to the central portion.
[0011] The disclosed embodiments can include a system for abating erosion of a shoreline. The system can include a main shell reef emplaced along the shoreline at least partially within the shore face and beyond the mean low water line. The shell reef can be formed from a plurality of adjacent shell modules. Each of the adjacent shell modules can be formed with two footers and a bridging member. The two footers can be generally parallel to a longitudinal axis of the shell module. Each footer can comprise an outer face. The bridging member can connect the footers, and can have a convex upper surface. This convex upper surface can peak at the longitudinal axis and extend downward on either side of the longitudinal axis to meet the outer face of each footer. A top of the main shell reef may be below the mean low water level. The shell modules may be placed to embed the footers of each shell module into the shore face.
[0012] In some embodiments, each footer may have an inner face, and the bridging member may have a concave undersurface peaking at the longitudinal axis and extending downward on either side of the longitudinal axis to meet the inner face of each footer.
[0013] In some embodiments, the adjacent shell modules may be formed with projections and recesses that interlock the adjacent shell modules to form the main shell reef.
[0014] In some embodiments, one or more additional shell reefs may be emplaced between the main shell reef and the mean low water line. These additional shell reefs may be angled towards the shoreline, and may be submerged below the mean low water level. The one or more additional shell reefs may contact the main shell reef.
[0015] The disclosed embodiments can include a method for abating erosion of a shoreline. This method can include the step of emplacing a main shell reef with a convex upper surface along a shoreline at least partially within a shore face and beyond the mean low water line. The top of the main shell reef may be below the mean low water level. This method can include the step of depositing fill at a location within the surf zone between the main shell reef and the toe of the coastal area.
[0016] In some embodiments, the method may further include the step of emplacing an additional shell reef between the main shell reef and the mean low water line. This additional shell reef may be angled towards the shoreline. The fill may be deposited up-drift of the additional shell reef. The additional shell reef may connect with the main shell reef. The fill may comprise at least one of sand, sand slurry, and dewatered sand slurry.
[0017] In some embodiments, the main shell reef may comprise a plurality of adjacent shell modules. The shell modules may be formed with projections and recesses that interlock the adjacent shell modules to form the main shell reef.
[0018] In some embodiments, the main shell reef may comprise a plurality of adjacent shell modules. Each shell module may be formed with two footers parallel to a longitudinal axis of the shell module. Emplacing the main shell reef may include embedding the footers of each shell module into the shore face.
[0019] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosed embodiments, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The drawings are not necessarily to scale or exhaustive. Instead, emphasis is generally placed upon illustrating the principles of the inventions described herein. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments consistent with the disclosure and together with the description, serve to explain the principles of the disclosure. In the drawings:
[0021] FIGS. 1A-1E depict five views of an exemplary modular shell for erosion abatement.
[0022] FIGS. 2A and 2B depict two exemplary configurations for interlocking modular shells for erosion abatement.
[0023] FIG. 3 depicts a top view of an exemplary system for abating erosion along a shoreline.
[0024] FIG. 4 depicts a schematic side view of a system for abating erosion along a shoreline.
[0025] FIG. 5 depicts an exemplary flowchart illustrating a method of abating erosion along a shoreline using a shell reef.
DETAILED DESCRIPTION
[0026] Reference will now be made in detail to the disclosed embodiments, examples of which are illustrated in the accompanying drawings. Wherever convenient, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
[0027] As used herein, the term “generally,” “about,” or “approximately” means within an acceptable error range for the particular value as determined by one of ordinary skill in the art, which will depend in part on how the value is measured or determined, e. g., the limitations of the measurements system. For example, “generally” can mean within one or more than one standard deviation per the practice in the art. Alternatively, “generally” can mean a range of up to 20%, such as up to 10%, up to 5%, and up to 1% of a given value.
[0028] As used herein, the term “toe” means the landward end of the beach, for example where the coast meets the beach. In some instances, the toe may be at the base of a bluff or dune.
[0029] As used herein, the term “mean low water level,” or “shoreline,” means the average of all the low water heights observed at a location over a period of time. In some embodiments, this period of time can be a National Tidal Datum Epoch. The term “mean low water line” means the elevation on a coastal area at the location corresponding to the mean low water level. The mean low water level and mean low water line can be approximate, and can be measured directly or obtained from a chart datum or similar data source.
[0030] As used herein, the term “mean high water level” means the average of all the high water heights observed at a location over a period of time. In some embodiments, this period of time can be a National Tidal Datum Epoch. As used herein, the term “mean high water line” means the elevation on a coastal area at the location corresponding to the mean high water level. The mean high water level and mean high water line can be approximate, and can be measured directly or obtained from a chart datum or similar data source.
[0031] As used herein, the term “shore face” means the zone extending from the low water line beyond the end of the surf zone to the closure depth, the depth beyond which no significant longshore or cross-shore transport take place due to littoral transport processes. As these littoral transport processes depend on wave climate, the closure depth may be defined by the some measure of significant wave height. For example, the closure depth may depend on the significant wave height exceeding twelve hours per year. Significant wave height can be the mean trough to crest wave height of the highest third of waves at a location. This definition of closure depth is not intended to be limiting, and one of skill in the art would be familiar with this definition and alternative suitable definitions.
[0032] As used herein, the term “surf zone” means the zone within which waves approaching the coastline typically commence breaking. This zone may be determined based on an expected wave height, such as the significant wave height exceeding twelve hours per year.
[0033] The disclosed embodiments can include shell reefs emplaced across or along the shore face. These shell reefs may mitigate erosion caused by wave action, wind forces, hydrostatic pressure, super saturation and liquefaction. These shell reefs are configured to allow the passage of waves, which can spread fill deposited on the shore face. These shell reefs also reduce the amount of fill scoured or sluiced off the shore face and lost to further cycles of beach accretion. In this manner, the disclosed embodiments maintain the gradient of the shore face and prevent undermining of the coast.
[0034] The disclosed shell reefs can comprise multiple shell modules. FIG. 1A depicts a three-point perspective view from above of exemplary shell module 100 . FIG. 1B depicts a top view of exemplary shell module 100 . FIG. 1C depicts a side view of exemplary shell module 100 . FIG. 1D depicts a slice through exemplary shell module 100 with the location and orientation indicated by the label “D” on FIG. 1C .
[0035] Shell module 100 may be fabricated from a heavy and corrosion-resistant material. This material can be porous. For example shell module 100 may be fabricated from a non-metallic material, such as a porous polymeric material. As an additional example, shell module 100 may be fabricated from a composite material including and one or more fillers and binders, such as a porous concrete. Such fillers may include an absorbent material that absorbs water when the shell is emplaced, counteracting buoyancy forces when submersed. For example, this filler may be activated charcoal. In some embodiments, shell module 100 may comprise a unitary structure. For example, shell module 100 may be formed using a mold. As an additional example, shell module 100 can comprise precast concrete. In some embodiments, shell module 100 may be fabricated from more than one material. For example, different components of shell module 100 (e.g., footers 110 and bridging member 120 ) may be fabricated from different materials. One or more of these components may be formed using a corresponding mold. The components may then be assembled. Shell module 100 may have a longitudinal axis 101 and a latitudinal axis 102 .
[0036] As shown in FIG. 1B , when viewed from above shell module 100 can have a generally square or rectangular peripheral outline. The shell module can have a first end and a second end, each generally orthogonal to longitudinal axis 101 and parallel to latitudinal axis 102 . In some aspects, shell module 100 can have a generally square or rectangular outline, with the addition of projections and recesses for interlocking adjacent modules. These projections and recesses can be arranged on the bridging member at the first and second ends of shell module 100 . In some embodiments, shell module 100 may be approximately 3 to 10 feet wide in the direction of latitudinal axis 102 . For example, shell module 100 can be approximately 4 to 7 feet wide in the direction of latitudinal axis 102 . In some embodiments, shell module 100 may be approximately 4 to 15 feet long in the direction of the longitudinal axis. For example, shell module 100 can be approximately 6 to 10 feet wide in the direction of latitudinal axis 102 . The height of shell module 100 may be chosen to may permit traversal by bottom-dwelling animals, such as crustaceans, and by people walking in the water. For example, shell module 100 may be approximately 1 to 4 feet high. As another example, shell module 100 may be approximately 2 to 3 feet high. In some embodiments, at least some of the upper surface of shell module 100 may be textured for better traction. For example, the upper surface of shell module 100 may be textured with a non-slip sand coating.
[0037] Shell module 100 can be formed with two footers (e.g., footer 110 ) connected by a bridging member 120 . In some embodiments, bridging member 120 may be configured to distribute the weight of shell module 100 approximately equally between footers 110 . The footers may be configured to anchor the shell module into the shore face. The footers can be formed with an outer face 111 and an inner face 113 . At least one of outer face 111 and inner face 112 can be approximately flat. The height of the outer faces 111 can be less than the height of the inner faces 113 . The outer faces 111 may be approximately 8 inches to 24 inches high. For example, the outer faces may be approximately 12 to 16 inches high. The inner faces may be approximately 2 to 20 inches high.
[0038] Outer faces 113 may be approximately aligned along planes angled outwards, such that the separation along the latitudinal axis between the outer faces 111 is greater at the bottom of footers 110 than at the top the footers 110 . In various aspects, the outer faces 113 may be approximately parallel to each other. In some aspects, the inner face 113 of each footer 110 may approximately parallel the outer face 111 of that footer. In various aspects, the inner faces 113 may be approximately parallel to each other.
[0039] Bridging member 120 can connect footers 110 and can be configured to reduce the scouring or sluicing of fill off the shore face, while allowing the passage of water through shell module 100 . As shown in FIG. 1A and FIG. 1D , in some embodiments bridging member 120 may arch between footers 110 . Such arching may elevate the undersurface of bridging member 120 off the shore face, concentrating the weight of bridging member 120 on the footers 110 and reducing the amount of material required to achieve a desired shell reef height. The area underneath bridging member 120 may also provide a secure breeding and hatching environment for small aquatic forms of life.
[0040] Bridging member 120 can be configured to maintain a relative position of footers 110 that generally distributes the weight of shell module 100 evenly between footers 110 when shell module 100 is submersed. For example, bridging member 120 may be approximately bilaterally symmetric around longitudinal axis 101 .
[0041] Bridging member 120 can comprise two perforated portions (e.g., perforated portion 121 and perforated portion 123 ) and connecting portion 125 . The two perforated portions may be generally flat. The two perforated portions may each be angled approximately 20 to 40 degrees with respect to the latitudinal axis of shell module 100 . For example, a perforated portion may slope downwards at a rate of approximately seven inches for every foot traveled from the longitudinal axis of shell module 100 . In some embodiments, the angles of the two perforated portions may differ. For example, the angle of a perforated portion 121 may be 20 degrees and the angle of perforated portion 123 may be 30 degrees.
[0042] The two perforated portions (e.g., perforated portion 121 and perforated portion 123 ) may include perforations 127 extending from the upper surface of bridging member 120 to the undersurface of bridging member 120 . In some embodiments, the number of perforations 127 may range from 2 to 10. In various embodiments, the number of perforations may differ between the two perforated portions. The perforations may extend from aperture on the upper surface of bridging member 120 to an aperture on the undersurface of bridging member 120 . The apertures on the upper and undersurfaces of bridging member 120 may be formed as slots, rectangles, circles, ovals, or other shapes. In some embodiments, the perforated portions can be formed with perforations, such as slots, extending parallel to the first or second ends (i.e., medially to laterally, or away from the longitudinal axis). In some aspects, the upper surface apertures may be dimensioned to prevent a human hand or foot from fitting into them. These perforations can facilitate passage of water and marine life through said module.
[0043] The perforations 127 may be tapered. For example, a dimension of an aperture on the upper surface may differ for a dimension of a corresponding aperture on the undersurface. As an additional example, as shown in FIG. 1C and FIG. 1D , the dimensions of a slot in bridging member 120 may taper from a smaller value at the upper surface aperture to a larger value at the lower surface aperture. This tapering can channel water exiting shell module 100 towards the shore into a jet, causing turbulence that dislodges material (e.g., silt, sand, or shingle) and transports this material further up the shore face. This tapering can also cause water entering shell module 100 and moving away from the shore to form a spray, slowing this retreating water and enhancing deposition of material.
[0044] Connecting portion 125 can be disposed along longitudinal axis 101 . In some embodiments, connecting portion 125 can be formed with a rounded top surface that offers low resistance to the movement of water over shell module 100 . For example, the top surface of connecting portion 125 can be approximately parabolic. In some aspects, connecting portion 125 may comprise perforations 127 . As with the perforations in perforated portion 121 and perforated portion 125 , the perforations in connecting portion 125 can extend from an aperture on the upper surface to an aperture on the undersurface of bridging member 120 . These perforations can be slots, rectangles circles, ovals, or other shapes.
[0045] FIG. 1E depicts a schematic of an exemplary footer, perforated portion, and connecting portion. As shown in FIG. 1E , footer 110 can be formed with an embedding portion 130 . This embedding portion can be configured to penetrate into the shore face (e.g., distance 149 into the shore face). For example, embedding portion 130 can be formed with bottom surface 131 and angled surface 133 . These surfaces may concentrate the weight of shell module 100 , enabling it to penetrate the shore face. In some aspects, angled surface 133 can evenly distribute the weight of shell module 100 . Embedding portion 130 can be configured to achieve the desired degree of penetration based on the soil bearing capacity. For example, a footer with a larger bottom surface 131 , larger angled surface 133 , or less-sloped angled surface 133 may be adapted for either shallower penetration into the shore face, or emplacement on soil with less weight-bearing capacity. Bottom surface 131 can be approximately flat. Bottom surface 131 can be contiguous with outer face 111 along a first edge, and can be contiguous with angled surface 133 along a second edge. Angled surface 133 can be approximately flat. Angled surface 133 can be contiguous with bottom surface 131 , and can be contiguous with inner face 113 . In some aspects, angled surface 133 may be parallel to the upper surface 145 of bridging member 120 . This may allow stacking of multiple units of shell module 100 . For example, when one shell module is placed atop another shell module, angled surface 133 of the top module may sit approximately flush with the upper surface 145 of the lower module.
[0046] In some embodiments, bridging member 120 may increase in thickness from the longitudinal axis to the footer. For example, the perforated portions (e.g., perforated portion 121 ) can increase in thickness from a first thickness 135 proximate to the connecting portion 110 to a second thickness 137 proximate to the footer. In various embodiments, the thickness of bridging member 120 may be approximately constant from the longitudinal axis to the footer.
[0047] As described above, bridging member 120 can arch between footers 110 . In some embodiments, bridging member 120 can have a convex upper surface 145 . This convex upper surface 145 may peak at longitudinal axis 101 . As shown in FIG. 1E , this convex upper surface 145 can extend downward to footers 110 , meeting outer face 111 . In some embodiments, bridging member 120 can have a concave undersurface 147 . This concave undersurface 147 may peak at longitudinal axis 101 . As shown in FIG. 1E , this concave undersurface 147 can extend downward to footers 110 , meeting inner face 113 . In some embodiments, one or more of upper surface 145 and undersurface 147 can be approximately hemispherical.
[0048] FIG. 2A and FIG. 2B depict schematics of interlocking adjacent shell modules, consistent with disclosed embodiments. As described above, the shell modules may be formed with a first end having a projection and a second end forming a complementary recess, enabling installation of adjacent shells in an interlocked configuration.
[0049] Shell module 100 a comprises a tongue and slot interlock 200 a formed by a projection on a first module interlocking with a recess on a second module. Projection 220 a can be aligned with longitudinal axis 101 , and can be formed with a variety of shapes. As shown in FIG. 2A , projection 220 a may have a generally trapezoidal peripheral outline. Alternatively, projection 220 a may have a generally semicircular peripheral outline, or generally rectangular peripheral outline. As shown in FIG. 2A , recess 210 a may be formed with a shape complementary to projection 220 a . Shell module 100 b comprises a multi-projection interlock 200 b formed by a projection and a recess on a first module interlocking with a projection and a recess on a second module. The projections, such as projection 220 b , can be offset from longitudinal axis 101 , and can be formed with a variety of shapes. As shown in FIG. 2B , the projections, such as projection 220 b , may have a generally rectangular peripheral outline. Alternatively, the projections may have a generally semicircular peripheral outline, or generally trapezoidal peripheral outline. As shown in FIG. 2B , the interlocking recesses, such as recess 210 b may be formed with shapes complementary to their corresponding projections, such as projection 220 b.
[0050] FIG. 3 depicts a top view of an exemplary system 300 for abating erosion along a shoreline, consistent with disclosed embodiments. As shown in FIG. 3 , different portions of the coastal area may be described by toe 301 , mean high water level 303 , mean low water level 305 , the outer boundary of the surf zone 307 , and the outer boundary of the shore face 309 . As depicted, surf zone boundary 307 is nearer the shoreline than shore face boundary 309 . As would be appreciated by one of skill in the art, the location of surf zone boundary 307 will depend on the current conditions, and may be further from the shoreline than shore face boundary 309 . For example, during periods of low tide and high waves, surf zone boundary 307 may be further from the shoreline than shore face boundary 309 .
[0051] System 300 can include main reef 310 emplaced along a shoreline. Main reef 310 can be emplaced at least partially within the shore face, between mean low water line 305 and shore face boundary 309 . As shown in FIG. 3 , main reef 310 can be emplaced entirely within the shore face. The separation between the shoreline and main reef 310 may be fixed, or may vary. In some embodiments, at least some of main reef 310 can be emplaced at a distance from the shoreline dependent upon the characteristics of the shoreline at that point. These characteristics may include the composition of the shore face (e.g., silt, sand, or shingle), the difference between mean high tide and mean low tide, and the slope of the shore face. For example, such portions of main reef 310 may be emplaced nearer the shoreline when the slope of the shore face is greater. In some embodiments, at least some of main reef 310 can be emplaced in a straight line, or angled towards or away from the shoreline, resulting in a varying distance between main reef 310 and the shoreline.
[0052] System 300 can include one or more additional reefs 320 . These additional reefs can be emplaced within the shore face. Additional reefs 320 may be angled towards the shoreline. For example, FIG. 3 depicts two additional reefs angled at approximately right angles to the shoreline. One of skill in the art would appreciated that additional reefs 320 can be emplaced at other angles, and the configuration depict is not intended to be limiting. Furthermore, should system 300 include multiple additional reefs, these additional reefs may be emplaced at differing angles. In some embodiments, additional reefs may be separated by between 40 and 120 feet. For example, additional reefs may be separated by approximately 80 feet.
[0053] As shown in FIG. 3 , in some embodiments the additional reefs may approximately contact main reef 310 . For example, each of additional reefs 320 may be emplaced with an end of the additional reef in physical contact with main reef 310 , or within two feet of main reef 310 . In various embodiments, one or more of additional reefs 320 may be separated from the main reef. For example, the additional reef may be emplaced with an end of the additional reef separated from main reef 310 by at least two feet.
[0054] As shown in FIG. 3 , in some embodiments, main reef 310 and/or additional reefs 320 can comprise a plurality of adjacent shell modules, as described above with regards to FIGS. 1A-2B . In various embodiments, at least some of these adjacent shell modules can generally contact each other, as shown in FIG. 3 . For example, the ends of these contacting adjacent shell modules can be in physical contact, or within two feet of each other. In various embodiments, least some of these adjacent shell modules can interlock, as shown in FIG. 2A and FIG. 2B .
[0055] Consistent with disclosed embodiments, shell modules comprising main reef 310 may differ in at least one dimension from shell modules comprising the at least one additional reef. For example, the shell modules comprising main reef 310 can be wider, longer, or higher than the shell modules comprising the at least one additional reef. As an additional example, lower component shell modules may allow the additional reef to angle towards the shoreline while remaining below the mean low water level, while shorter and/or narrower component shell modules may enable the emplacement of the at least one adjacent reef to better follow the slope of the shore face.
[0056] FIG. 4 depicts a profile view of the exemplary system 300 for abating erosion along a shoreline, consistent with disclosed embodiments. As shown in FIG. 4 , coastal area 400 may include beach 410 , extending from toe 301 to mean high water level 303 , shore face 403 , extending from low water level 305 to shore face boundary 309 , and surf zone 405 , extending from high water line 303 to surf zone boundary 307 . As described above with regard to FIG. 3 , system 300 may comprise main reef 310 . Main reef 310 may be emplaced at least partially within shore face 403 , and may be emplaced along the shoreline. Main reef 310 may be emplaced such that the top of main reef 310 is below the mean lower water level.
[0057] In some embodiments, as shown in FIG. 4 , system 300 may comprise one or more additional reefs 310 . As described above with regard to FIG. 3 , these additional reefs may be emplaced between main shell reef 310 and mean low water line 305 . In some embodiments, the one or more additional shell reefs can be submerged below the mean low water level 409 .
[0058] In some embodiments, fill 410 can be deposited on the landward side of main reef 310 . For example, fill 410 can be deposited in surf zone 405 between mean high water line 303 and main reef 310 . Alternatively or additionally, fill 410 may be deposited on beach 401 within the run-up limit (the extent of swash). Fill 410 can include one or more of silt, sand, sand slurry, de-watered sand, or other beach nourishment materials known to one of skill in the art. Fill 410 can be deposited by one or more of pumping fill into position or dumping fill into position, or another method known to one of skill in the art. In some embodiments, fill 410 may be deposited up-drift of any additional reef, so that the longshore current carries fill 410 toward the additional reefs.
[0059] Consistent with disclosed embodiments, system 300 can abate erosion of the shore face. As shown in FIG. 4 , main reef 310 can support a decreased slope 420 in coastal area 400 between the emplacement location of main reef 310 and beach 401 . Main reef 310 can anchor this decreased slope, decreasing backwash and preventing currents and/or waves from scouring or sluicing fill 410 away from the beach, where it would be lost to cycles of beach accretion. Main reef 310 can also allow waves to continue spreading fill 410 onto beach 401 and shore face 403 , enabling accretion of beach 401 in naturally cohesive layers. Main reef 310 can also enable deposition of fill beyond the emplacement location of main reef 310 . Such additional deposits 430 can further anchor main reef 310 into the shore face and additionally protect the coastal area.
[0060] FIG. 5 depicts an exemplary flowchart illustrating a method of abating erosion along a shoreline using a shell reef, consistent with disclosed embodiments. After initial step 501 , the method may comprise determination of the placement of the shell reef in step 503 . This determination may depend on information regarding the coastal area along which the shell reef will be emplaced. For example, this determination may depend upon the composition of the share face (e.g., silt, sand, shingle, or other material), the mean low water level, the mean high water level, and the outer boundaries of the surf zone and the sea face. This information may be obtained by direct measurements according to methods known to one of skill in the art, or from charts or databases of coastal data. This determination may also depend upon the desired goals of the erosion abatement operation. For example, this determination may depend upon the desired slope of the resulting shore face following emplacement of the shell reef. As an additional example, a lesser slope may require a bigger shell reef, placed further out from the shoreline. Creation of a lesser slope may also require emplacement of additional reefs, as described above with regards to FIG. 3 and FIG. 4 . Additional reefs may also be required when the beach nourishment is intended to be confined to a particular region of the coastline.
[0061] The characteristics determined may include the length of the main reef, the separation of the main reef from the shoreline, and the dimensions of the main reef. In some embodiments, these characteristics may also include the dimensions of a plurality of shell modules comprising the shell reef. Additionally, these characteristics may further include determining whether adjacent shell modules interlock, and the arrangement of projections and recesses between adjacent, interlocking shell modules. The characteristics determined may also include the fill type and transport method.
[0062] The shell reef may be constructed in step 505 according to the placement characteristics determined in step 503 . In some embodiments, modules may be transported to the emplacement location on a vessel, such as a barge, or using a motor vehicle, such as a semitrailer. In some embodiments, constructing the shell reef may comprise emplacing shell modules to form a main shell reef. In various embodiments, constructing the shell reef may comprise emplacing shell modules to form one or more additional shell reefs. These shell modules may have the configuration described above with regards to FIG. 1A to FIG. 2B and may be emplaced to form an erosion abatement system such as system 300 , described above with regard to FIG. 3 and FIG. 4 . Construction of the shell reefs may be accomplished with construction equipment such as cranes, helicopters, bulldozers, barges, or similar equipment known to one of skill in the art according to methods known to one of skill in the art. Construction may be accomplished while minimizing use of heavy construction equipment on the beach. For example, components of the shell reef may be transported using one or more barges and emplaced using one or more crane vessels and/or helicopters. In some embodiments, component shell reefs may be placed to embedding at least a portion of footers 110 into the shore face. The degree of embedding may be predetermined or dependent upon the characteristics of the shore face at the location of emplacement. For example, the degree of embedding may depend upon the orientation of outer face 111 , the orientation of angled surface 133 , and the extent of bottom surface 131 .
[0063] Fill may be deposited at a location between the toe of the coastal area and the shell reef in step 507 , as shown in FIG. 4 . For example, fill may be deposited in the surf zone between the beach and the shell reef. As an additional example, fill may be deposited on the beach within the run-up zone, where swash from breaking waves may spread the fill over the beach. In embodiments including additional reefs, the fill may be deposited up-drift of the shell reef. The fill may include silt, sand, sand slurry, de-watered sand, or other materials known in the art for beach nourishment. The fill may be deposited by pumping. For example, slurry may be conveyed using a pipeline from a dredging barge to the fill deposit location. The fill may be deposited by dumping. For example, fill may be conveyed by barge or truck to the fill deposit location. As would be understood by one of skill in the art, the particular method of depositing the fill is not intended to be limiting. After step 507 , the method can proceed to an end 509 .
[0064] Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed embodiments disclosed herein. Moreover, while illustrative embodiments have been described herein, the scope includes any and all embodiments having equivalent elements, modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations or alterations based on the present disclosure. The elements in the claims are to be interpreted broadly based on the language employed in the claims and not limited to examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive. Further, the steps of the disclosed methods can be modified in any manner, including by reordering steps or inserting or deleting steps. It is intended, therefore, that the specification and examples be considered as example only, with a true scope and spirit being indicated by the following claims and their full scope of equivalents. | The disclosed systems, methods, and apparatuses may combat coastal erosion using a shell module shaped to enable retention of sand on a beach and shore face. The shell module may be shaped to minimizing interference with recreational use of the beach and providing a beneficial environment for desirable sea life. The modular shell can be conveniently transported and emplaced in shell reefs. These shell reefs may comprise multiple, optionally interlocking shell modules. These shell reefs can prevent fill, such as sand, de-watered sand, or sand slurry from being scoured and sluiced out to sea. The disclosed systems and methods harness the energy of incoming and returning waves, including tidal and surf action, to assist in spreading the fill, recreating a natural beach, complete with layers of sand capable of resisting the scouring force of ocean waves and currents. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to monitoring respirations of a patient, and more specifically to impedance pneumography, which is a technique for monitoring respirations by monitoring changes in electrical impedance caused by the expansion and contraction of the thoracic cavity of the patient during respiration.
2. Description of the Prior Art
Typically, a differential, constant amplitude AC examination current is applied to the body of a patient for detecting patient respirations by measuring changes in the transthoracic impedance of the patient. The examination current is applied to the patient by two of the electrodes normally used for ECG monitoring. The examination current is passed through the thoracic cavity of the patient and, due to the constant amplitude examination current passing through a transthoracic impedance that changes with patient respirations, voltage modulations are created at the ECG electrodes in accordance with the patient respirations. The resulting voltage modulations are typically detected by a synchronous voltage detector, connected to the same pair of electrodes as was used for applying the examination current, such as the right arm (RA) and left arm (LA) electrodes.
The cables used for connecting the examination current and voltage detector to the patient contain capacitive reactances which tends to shunt a portion of the examination current around the patient. One effect of this shunting is that the system gain, as expressed in Volts/Ohm, will have a dependency on the baseline level of the transthoracic impedance, as well as the level of any impedance placed in series with the patient, such as resistances for protecting the monitoring circuitry from defibrillator voltages which may be applied to the patient. This dependency makes detecting the small respiration induced changes in impedance more difficult (that is, such a dependency making it difficult to set absolute signal detection threshold levels). Another effect is that the induced voltage becomes sensitive to changes in the frequency of the examination current. Any phase or frequency jitter in the examination current signals, or the clock signals used to detect the examination current, will be converted to a voltage noise during detection by the synchronous voltage detector. The above-noted shunting of the examination current, changes in the system gain, and voltage noise result in signal artifacts in the induced voltage modulations which reduce the accuracy of the respiration detection circuitry.
It is an object of the present invention to provide an AC examination current source which will solve these undesirable effects, while providing a current source which is relatively low in cost, which will present minimum load to ECG signals acquired by the electrodes, and able to be easily manufactured using integrated circuit technology.
A prior art respiration monitor manufactured by Hewlett-Packard (believed to be sold under the trademark CLOVER) applies a fixed frequency sine wave to an impedance bridge, one leg of which is connected to the thoracic cavity of a patient via a transformer. It is believed that the magnetizing inductance of the transformer may be intended to at least partially compensate for the capacitance in the patient cable although this is not specifically known. The output of the bridge is fed to a synchronous detector for developing the respiration signal in accordance with known techniques. Although the transformer in this monitor may provide some compensation for the capacitance of the patient cable, the technique undesirably requires the use of a transformer, which is bulky and not well suited for incorporation with integrated circuit technology. Additionally, this technique requires a sinewave examination current, which is somewhat difficult and costly to generate using digital circuitry.
SUMMARY OF THE INVENTION
An apparatus for monitoring the expansion and contraction of the thoracic cavity of a patient caused by respirations comprises, generating means for generating an AC examination current signal, coupling means for applying the examination current signal to the patient so that the examination current passes through the thoracic cavity of the patient, but at least a portion of the current does not pass through the thoracic cavity of the patient, detecting means coupled to the coupling means for detecting an amplitude modulated voltage signal developed across the patient in response to the application of the examination current and variation of the transthoracic impedance of the patient due to respiration, and current modifying means coupled with the generating means for modifying the AC examination current during application to the patient so that the portion of the examination current which does not pass through the patient is at least partially compensated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates in block diagram form a prior art respiration monitor;
FIG. 2 illustrates in block diagram form a respiration monitor constructed in accordance with the principles of the present invention;
FIG. 3 illustrates partially in block diagram form and partially in schematic diagram form the respiration monitor shown in FIG. 2; and
FIG. 4 illustrates in block diagram form the functional operation of a portion of the schematic shown in FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a prior art respiration monitor 8 wherein a differential current source 10 generates two identical, but differential (180° out of phase), AC examination currents. The differential currents are applied to patient mounted electrodes 12 and 14, respectively, via a patient connected cable 16. Typically, the electrodes are of the type used for EKG monitoring, and patient cable 16 is the EKG cable used to connect the EKG electrodes to an EKG monitor. In this case, EKG signal processing circuitry (not shown) would also be connected to cable 16 in parallel with respiration circuitry 18, for developing and displaying EKG waveforms, as well known. As also well known, the body of a patient P presents a varying impedance Z between electrodes 12 and 14, the variations in the patient impedance corresponding to the expansion and contraction of the transthoracic cavity of the patient in response to patient respirations. Respiration circuitry 18 within the monitor is connected to the electrodes 12 and 14 via cable 16 for sensing amplitude modulations of a voltage developed between electrodes 12 and 14 due to the applied AC examination current and the patient respirations. In a manner well known to those of ordinary skill in the art, these sensed amplitude modulations are processed for developing a respiration signal which may be used for display and/or alarm monitoring of the respirations of the patient. Also illustrated are C C , the effective capacitance of cable 16, and C B and R P , comprising a DC blocking capacitor and a high voltage protection resistor, respectively.
The effective capacitance C C of cable 16 tends to shunt a portion of the AC examination current around, rather than through, the patient. One major effect of this shunting is a reduced signal level of the induced voltage modulations, thereby reducing the ability to accurately monitor the changes in patient impedance, which is on the order of only 1 or 2 Ohms out of approximately 600 to 6000 Ohms of patient impedance. At approximately 5000-6000 Ohms of patient impedance, current shunting by the cable is significant. Other undesirable and related effects of the cable capacitance C C are the variation and gain, as expressed in Volts/Ohm, and the conversion into voltage variations by the synchronous detector of frequency and/or phase jitter in the examination current, as previously noted in the Background portion of this specification.
In FIG. 2, a block diagram of a respiration monitor constructed in accordance with the principles of the present invention is shown. Circuits and components that are substantially the same in FIGS. 1 and 2 are similarly numbered. Basically, there are at least two improvements over the prior art. Firstly, compensation networks 20 and 22 are incorporated with the differential outputs of current source 10 forming a modified current source 10' and secondly, in the preferred embodiment, the differential current source is provided using a switched "flying" capacitor circuit arrangement.
As shown in FIG. 2, a differential current source 11 provides a square wave examination current 24 (of, for example, ±100 μA), and compensation networks 20 and 22 modify the examination current so as to develop a compensated current at the respective outputs of current source 11' which has an overshoot at its leading edges, as illustrated by waveform 26. Waveform 28 is illustrative of the voltage developed across the patient in response to application to the patient of the compensated examination current, which voltage is transmitted to the respiration detection circuits 18 via cable 16. Note that the level transitions in waveform 28 are substantially rectangular, wherein if the compensated examination current, as illustrate by waveform 26, were not provided, a portion of the examination current will initially be shunted across the patient by the capacitance C c of cable 16, and then slowly increase thereafter. This undesired effect of the cable capacitance, if left uncompensated, would result in a voltage waveform 28 having degraded leading edges at the signal level transitions, such as shown by the curved dashed-line portions in waveform 28. These curved portions indicate a reduced amplitude level voltage signal (i.e., one with a reduced S/N) into the respiration detector (as well as an unwanted amplitude level variation), which, as previously noted, can result in monitoring inaccuracies when developing the respiration signal. Compensation networks 20 and 22 develop the compensated examination current so that the combined effect of the overshoot in the examination current with the shunting effect of cable capacitor C c is a substantially square wave voltage waveform 28 at the input to respiration circuitry 18.
FIG. 3 illustrates partially in block diagram form and partially in detailed schematic diagram form a respiration monitor constructed in accordance with the principles of the present invention, including the compensated current source 11'. Note, since the compensated current source 11' develops two identical differential AC currents that are 180° out of phase, and basically comprises two identical current sources, details of only one-half of the circuitry will be described. In this regard, in conjunction with this description, reference should also be made to the functional block diagram shown in FIG. 4, which functionally describes the operation of one-half of the switching arrangement forming current source 11. A voltage reference 50 comprises series connected diodes D 1 and D 2 , which are forward biased via resistors R 1 and R 2 connected to power supply voltages of +5 volts and -5 volts, respectively. First and second substantially identical switching arrangements 52 and 54 are simultaneously coupled to the positive and negative sides, respectively, of voltage reference source 50 for developing in a complimentary manner first and second differential voltage signals, respectively. A system clock (not shown) provides complimentary (180° out of phase) clock signals CLK + and CLK - , which are provided to switching arrangements 52 and 54, respectively. The first and second differential voltage signals provided by switching arrangements 52 and 54 are then converted to current signals via first and second voltage to current (V/I) converters 56 and 58, respectively.
In accordance with the principles of the invention, the examination current signals developed at the output of converters 56 and 58 are modified by compensation networks 60 and 62, respectively, before being applied to the patient via the previously described blocking capacitor, high voltage protection resistor, patient cable and patient electrodes. The modification is by an amount sufficient to substantially compensate for the undesirable shunting of the examination current around the patient.
Referring again to FIGS. 3 and 4, voltage reference 50 provides a low impedance reference source for charging a "flying" capacitor C 9 via a clocked integrated circuit switch arrangement 54, which includes switch portions 54A that are normally closed in response to the CLK - clock signals, as shown. On the first half-cycle of the CLK - clock signal, switch portion 54A connects capacitor C 9 across reference voltage source 50. On the second half-cycle of CLK - clock signal, switch portion 54B connects capacitor C 9 across capacitor C 10 , thereby maintaining a steady state voltage on capacitor C 10 at a value equal to the reference voltage. A reversing switch arrangement comprising switches 54C and 54D alternately reverses the polarity of the voltage developed across capacitor C 10 for application to a voltage to current (V/I) converter amplifier 58. Amplifier 58 forces the voltage on capacitor C 10 to appear across compensation network 62. The timing of switches 54C and 54D are controlled by the CLK - clock signal, with normal switch positions as shown in FIG. 3. The output of amplifier 58 is provided as the examination current after being modified via compensation network 62. Network 62 comprises a parallel connection of R 4 and C 14 .
Compensation of the current source is achieved as follows. At the instant the voltage across the compensation network 62 changes polarity, due to the operation of reversing switch 54C/54D, a transient current substantially larger than the steady state current is created by a rapid charging action of capacitor C 14 by amplifier 58. This transient current is used to rapidly charge the distributed capacitance in patient cable 16. This transient current surge then decays at an exponential rate, as determined by the RC time constant of R 4 and C 14 of compensation network 62. If the product of R 4 and C 14 is made to be substantially equal to the RC product formed by the transthoracic impedance of the patient and the distributed capacitance of the patient cable, then the effects of cable capacitance can be substantially diminished. The extra current provided by current source 11' compensates for the amount of examination current that shunts around the patient due to cable capacitance C C , rather than flowing through his transthoracic cavity. This will maximize the S/N of the developed voltage modulation signal applied to the synchronous detector 64 at the input of respiration detection circuitry 18. Synchronous detector 64 operates in a manner well known to those of ordinary skill in the art, and is responsive to the CLK + and CLK - clock signals for detecting the AC voltage, with amplitude modulations corresponding to respirations, generated at its output.
The setting of R 4 and C 14 can be made at the factory during manufacture, using fixed valves that provide appropriate compensation for typical patients, as determined by trial and error during circuit design. Alternatively, the output of the synchronous detector portion of respiration circuit 18 could be monitored for a predetermined output level while C 14 is manually adjusted by the user.
Thus, there has been shown and described a novel method and apparatus which satisfies all the objects and advantages sought therefore. Many changes, modifications, variations and other uses and applications of the subject invention will, however, become apparent to those skilled in the art after considering this specification and its accompanying drawings, which disclose preferred embodiments thereof. For example, the above-noted adjustment of capacitor C 14 can be made automatic by using a varactor diode as C 14 and developing a control signal from the output of the synchronous detector which is applied in a feedback manner to diode C 14 . Furthermore, although current source 11 is illustrated using a switched capacitor arrangement, other arrangements for generating a current source are also possible, such as a large valve resistor, but which are not as advantageous as the illustrated embodiment. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow. | An apparatus for monitoring the expansion and contraction of the thoracic cavity of a patient caused by respirations comprises, generating means for generating an AC examination current signal, coupling means for applying the examination current signal to the patient so that the examination current passes through the thoracic cavity of the patient, but at least a portion of the current does not pass through the thoracic cavity of the patient, detecting means coupled to the coupling means for detecting an amplitude modulated voltage signal developed across the patient in response to the application of the examination current and variation of the transthoracic impedance of the patient due to respiration, and current modifying means coupled with the generating means for modifying the AC examination current during application to the patient so that the portion of the examination current which does not pass through the patient is at least partially compensated. | 0 |
TECHNICAL FIELD
The present invention relates generally to personal training equipment such as that used in the development of martial arts skills and, more particularly, to equipment of the foregoing type that enables the room or other space in which the equipment is placed to be productively used for other purposes when the equipment is not in use, notwithstanding the continued presence of the equipment.
BACKGROUND
Martial arts schools are typically located in rented space within shopping centers and other commercial building structures. The open class room spaces typically found in such areas are conducive to handling sizable groups of students for group exercises and education. However, martial arts also involves considerable resistance training and work on such things as foot and eye coordination, eye and hand coordination, and balance. This frequently involves the use of suspended bags and other devices that can be kicked and struck in the appropriate manner. Rented space is not well-suited for this type of equipment.
For example, the building spaces typically have suspended ceilings that are incapable of supporting the significant loads imposed by hanging the equipment. Further, attachment to rafters and walls may cause extensive shaking and vibration of the building structure, leading to possible damage and, in any event, becoming a nuisance to other tenants. Moreover, any kind of permanent mounting arrangement for the equipment makes its virtually impossible to conduct exercises as a group because the equipment becomes an obstacle. While individual, free-standing bag stands and the like are an option, they still present obstacles that must be dealt with when a free and open class space is desired, and they are not an efficient use of available floor space.
Many individuals are also interested in having personal workout equipment in their own homes or offices. However, conventional equipment occupies such an inordinate amount of floor space and is so inconvenient to move and disassemble that the selected workout area usually needs to be dedicated solely to that one particular purpose. Most homes and offices simply do not have that luxury.
SUMMARY OF THE INVENTION
The present invention provides a workout equipment system, especially but not exclusively suited for martial arts training, that can be quickly and easily placed in either deployed or stowed conditions to allow the room space to be selectively used for a wide variety of different purposes including, but not limited to, workouts and training. It is particularly well-suited for use in a classroom setting where large groups of students are involved. However, the invention is also ideally suited for embodiment in a smaller, home and office use system for individuals.
One preferred embodiment of the present invention contemplates a relatively tall, free-standing, hollow framework or superstructure having a number of upright supporting legs and overhead beams that span and interconnect the legs so as to effectively define an open space under the beams and within the interior of the framework. Carriages or hangers are adjustably moveable along at least certain of the overhead beams to support free-hanging training devices such as kick bags and the like. Each of the hangers can be temporarily locked in any one of a number of selected positions along the length of its supporting beam so as to position one or more of the training devices out within the open space, effectively converting it into a training and skill area. The hangers with their associated training devices can, however, be selectively moved along the overhead beams into stored positions adjacent the outer limits of the framework, such as near a wall of the room, thus freeing up a large open area of the room for group exercises or other group activities. In one particularly preferred form of the invention, the various upright legs and horizontal beams are constructed from end-to-end sections that are bolted together for quick and easy installation and removal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a typical room within a building employing a system in accordance with the principles of the present invention, and showing exemplary training devices in deployed positions out in the interior space defined by the framework;
FIG. 2 is an isometric view similar to FIG. 1 but illustrating the training devices collected off to one side of the space so as to free up the area for other types of activities such as, in the illustrated embodiment, exercises and teaching;
FIG. 3 is an enlarged, fragmentary isometric view of portions of the framework illustrating details of construction;
FIG. 4 is a further enlarged fragmentary elevational view of one of the hangers and supporting beams of the framework with parts broken away and shown in cross-section to reveal details of construction; and
FIG. 5 is a vertical cross-sectional view through the hanger of FIG. 4 taken substantially along line 5 — 5 of FIG. 4 .
DETAILED DESCRIPTION
The present invention is susceptible of embodiment in many different forms. While the drawings illustrate and the specification describes certain preferred embodiments of the invention, it is to be understood that such disclosure is by way of example only. There is no intent to limit the principles of the present invention to the particular disclosed embodiments.
FIG. 1 shows a typical room 10 within the interior of a building, such room having a floor 12 , a ceiling 14 and upright walls 16 extending between floor 12 and ceiling 14 . A door 18 provides ingress and egress to the space within room 10 . By way of example, the room 10 is depicted as being large enough to serve as a classroom for holding a group of students, although it could be a relatively small space suitable for individual use only such as found in the home or office.
In accordance with the present invention, the room 10 is provided with a training system that includes a relatively tall, free-standing, multi-sided open framework 10 including a number of laterally spaced apart, upright legs 22 that are taller than the normal height of persons using the room 10 . At the upper ends of legs 22 , overhead structure in the nature of a plurality of horizontal beams 24 interconnect the legs 22 to tie the assembly together into a rigid unit that does not rely upon ceiling 14 or walls 16 for support. The lower ends of legs 22 are provided with rectangular, flat feet 26 that are considerably larger in surface area than the cross-sectional area of each leg 22 so as to contribute to the stability of free-standing framework 20 . A number of lower horizontal beams 28 near floor 12 may be provided between certain of the legs 22 if desired. In the illustrated embodiment, the framework 20 is rectangular as viewed in plan, although it will be appreciated that a number of other shapes may be obtained and utilized without departing from the principles of the present invention.
At least certain of the upper beams 24 are provided with a series of hangers 30 that are used to suspend training devices such as bags 32 down into the training and class space defined by the interior of the framework 20 . Hangers 30 are moveable along their respective beams 24 such that the bags 32 may be deployed as illustrated for example in FIG. 1 in a use position occupying much of the training space, or a stored position as illustrated in FIG. 2 wherein the bags of each beam are collected together in a group adjacent one leg 22 of the framework and one of the walls 16 of the room. When bags 32 are in their stored positions of FIG. 2, the interior space is opened up to provide an essentially unobstructed area. In the case of a class room setting, various types of group exercises and teaching can be carried out in the available space. In the case of the individual home or office, the opened up space (such as in the basement or garage) can be used for any number of different purposes.
It will be noted that, as an option, training devices can also be stretched between the lower beams 28 and corresponding overhead beams 24 , as exemplified by the small bags 34 in FIGS. 1 and 2. The lower beams 28 can also be used to support other types of equipment, if desired.
As illustrated in FIG. 3, each of the legs 22 is preferably constructed in sections so that framework 20 may be assembled and erected on-site. As illustrated in FIG. 3, a typical leg 22 includes a tubular lower section 36 and a tubular upper section 38 that are held in end-to-end alignment with one another to present a continuous length for the leg 22 . A tubular insert 40 of slightly smaller cross-sectional size than leg 22 but complementary shaped relative thereto is received within leg 22 in such a manner that one half projects up into the upper section 38 while the lower half projects down into the lower section 36 . Fasteners in the nature of bolts 42 pass through holes 44 in section 36 and 38 and into corresponding, aligned holes 46 in insert 40 for the purpose of securing the sections 36 and 38 to the common insert 40 . Insert 40 and bolts 42 thus serve as a coupling for the two sections 36 , 38 of each leg 22 . To facilitate assembly and erection of the framework 20 , the insert 40 could be pre-welded to one of the sections 36 , 38 , eliminating one set of the bolts 42 .
The upper beams 24 may be constructed similarly to legs 22 , as also illustrated particularly in FIGS. 3 and 4. In the particular embodiment illustrated, each of the upper beams 24 that carries a hanger 30 is constructed in three end-to-end sections, two of which are illustrated in FIG. 3 and are denoted by the numerals 48 and 50 . A coupling for interconnecting the two sections 48 , 50 comprises a tubular insert 52 that is slightly smaller in cross-section than the tubular sections 48 and 50 so as to be complementally received with in those structures. One-half of insert 52 projects into section 48 , while the other half projects into section 50 . Fasteners in the nature of bolts 54 pass through holes 56 in beam sections 48 , 50 and into holes 58 in insert 52 . As perhaps shown best in FIG. 4, the upper holes 58 in insert 52 are threaded so as to threadably receive the upper end of bolt 54 , eliminating the need for nuts as used on the legs 22 as shown in FIG. 3 . As with the legs 22 , the insert 52 could be pre-welded to one of the sections 48 , 50 to facilitate assembly and erection.
Opposite ends of each beam 24 are provided with mounting plates 60 that abut the corresponding flat surface of the leg 22 to which the beam 24 is attached. Bolts 62 fasten the mounting plates 60 to the corresponding leg 22 . In the illustrated embodiment, the beams 24 that carry hangers 30 are significantly larger in cross-sectional configuration than other beams that do not carry any particular load, as illustrated, for example, in FIG. 3 . If desired, all beams could be of the same cross-sectional size and configuration.
As illustrated in FIGS. 3, 4 and 5 , each hanger 30 comprises a relatively large, rectangular sleeve 64 that is received on the corresponding beam 24 . A pair of bolts 66 and 68 across the upper portions of sleeve 64 and at opposite ends thereof rotatably support a pair of anti-friction rollers 70 and 72 that ride along the top surface of beam 24 to render hangers 30 moveable axially of the beams 24 . Longitudinal, Nylon anti-friction guide strips 64 a and 64 b on opposite interior walls of sleeve 64 prevent lateral movement on beam 24 , while transverse Nylon anti-friction guide strips 64 c and 64 d at opposite ends of sleeve 64 help prevent untoward vertical movement relative to beam 24 .
Each hanger 30 includes a releaseable lock 74 that is used to temporarily latch the hanger in a selected position along the length of its beam 24 . In a preferred embodiment, lock 74 includes a spring-biased pin 76 on sleeve 64 that is yieldably urged toward the bottom of beam 24 for reception within any one of a number of locking holes 78 along the bottom of beam 24 . Pin 76 is carried by a hollow bracket 80 fixed to the bottom of sleeve 64 , there being a compression spring 82 within bracket 80 that urges pin 76 toward the beam 24 . A clip 84 inside of bracket 80 and fixed to pin 76 traps spring 82 against the lower interior surface of bracket 80 . For convenience, pin 76 may be provided with a pull ring 86 at its lower end to facilitate gripping and actuation by a person standing within the interior of framework 20 below the beams 24 . A suitable strap or pull rope (not shown) may be tied to ring 86 to facilitate release of pin 76 and to provide a convenient way for the user to pull the unlocked hanger along beam 24 .
Each sleeve 64 also includes an eye bolt 88 that is fixed to the bottom of sleeve 64 and projects downwardly therefrom. Eye bolt 88 may be used to secure the suspension chains 90 or other hanging means for bags 32 to the hanger 30 .
In use of the invention, it will be appreciated that the system can be relatively quickly and easily erected at a selected site without requiring any modification to existing floors, walls and ceilings. Although it is not absolutely essential that the framework 20 be totally free-standing, and it is within the concepts of the present invention to provide additional stabilizing structures if desired, there is no need for such supplemental stabilizing means in order to enjoy the benefits of the invention. By virtue of the fact that framework 20 is comprised of a number of component parts that are secured together by releaseable fasteners, framework 20 can be readily erected on-site in a fairly short period of time and arranged to take on virtually any desired configuration. Although a simple rectangular overall configuration has been illustrated in one preferred embodiment, other shapes that will satisfy the specific needs and desires of the user are within the scope of the present invention.
It will be appreciated that when all of the bags 32 or other training devices are moved off to the side in stored positions as illustrated in FIGS. 2, the space within room 10 is largely unobstructed by the system. Because the overhead beams 24 are disposed at a height significantly above normal human height, they present no obstruction whatever to activity therebeneath. Although the upright legs 22 occupy a certain amount of floor space at eye level, as do the bags 32 , the space occupied by those structures is minimal compared to the open space available within the room.
It will be appreciated further that it is not necessary for all of the bags 32 to be either stored or deployed. Depending upon the activities or use planned, such as for a classroom setting, only a few of the bags 32 might be positioned out in the space for training use by a relatively few number of students, while the rest of the area remains open and free for group exercises and the like. Or, the reverse situation could obtain where most of the area is occupied by the bags in a deployed position, while along one end of the area the bags are fully moved over to their stored positions. In any event, it will be appreciated that great flexibility is afforded by the present invention while at the same time avoiding the significant costs and other problems associated with modifying or reconstructing the walls, ceiling or floor of the room.
Although preferred forms of the invention have been described above, it is to be recognized that such disclosure is by way of illustration only, and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiments, as hereinabove set forth, could be readily made by those skilled in the art without departing from the spirit of the present invention.
The inventor(s) hereby state(s) his/their intent to rely on the doctrine of equivalents to determine and assess the reasonably fair scope of his/their invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set out in the following claims. | The system includes a tall, open, multi-sided framework having a number of laterally spaced, upright legs that are interconnected by overhead structure in the form of elongated beams. The beams are located above normal human height so as to avoid interference with activities conducted within the open space defined by the framework. A number of trolley-like hangers are adjustably moveable along at least certain of the overhead beams for the purpose of suspending training devices such as kick bags or the like down into the space. Releaseable locks on the hangers are accessible by persons standing beneath the beams to facilitate selective engagement and disengagement of the locks and manual pulling of the hangers along the rails to either deployed positions out in the room space or stored positions adjacent the side of the framework. The framework is constructed in sections using removeable fasteners so as to facilitate on-site erection and disassembly. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to systems and methods for post-processing decompressed images in order to minimize perceptual artifacts due to prior image compression, and in particular to such prior image compression methods that process images as independent blocks of pixels.
2. Description of the Related Art
Many important image compression methods process images as independent blocks of pixels. For example, such families of compression standards as JPEG, MPEG, H.320, and so forth, specify a step involving discrete cosine transformation (“DCT”) of independent, non-overlapping 8×8 blocks of pixels in the source image followed by quantization of the resulting transform coefficients. See, e.g., Jack, 1996 , Video Demystified , HighText Interactive Inc., San Diego, Calif. The quantized transform coefficients are transmitted from a transmitter-encoder to a receiver-decoder. Such transformation and quantization together achieve compression by exploiting the significant correlations that typically occur between the values of pixels in 8×8 blocks, but result in loss of image information (“lossy” compression), the coarser the quantization the greater the loss.
Decompressing images so compressed, which necessarily involves steps of dequantization and inverse DCT of the received quantized coefficients in order to derive a received decompressed image, can lead to what are called herein “blocking artifacts” in the following manner. In certain areas of a received image, the quantization errors introduced can become especially apparent and even objectionable. Especially, in regions where the image is fairly smooth, with little high spatial frequencies components, errors in the low spatial frequency components can make the individual, independent 8×8 blocks perceptually apparent. This is especially so if low frequency components, which smoothed the block-to-block boundaries in the source image, are set to zero.
Several methods of reducing such blocking artifacts are available in the current state of the art. Simple lowpass filtering applied to the decompressed image can blur blocking artifacts and reduce their prominence to some extent, but it necessarily leads also to an overall degraded sharpness in the image. Blocks can be overlapped in the source image in order to redundantly encode block-to-block boundaries, but at the cost of decreased compression and increased required communication bandwidth.
Further, Pennebaker et al., 1993 , JPEG Still Image Compression , Van Nostrand Reinhard, chap. 16, discloses JPEG block smoothing by fitting quadratic surfaces to the average values of pixels (equivalent to the “DC”, or lowest order, transform coefficient) in adjacent blocks, a computationally complex process. Lakhani, 1996, “Improved Image Reproduction from DC Components”, Opt. Eng. 35:3449-2452, discloses equations for predicting low frequency transform coefficients from DC coefficients that are improved from those in the JPEG standard. Finally, Jeon et al., 1995, Blocking Artifacts Reduction in Image Coding Based on Minimum Block Boundary Discontinuity, Proc SPIE 2501:189-209, discloses a complex and computationally expensive iterative method for zeroing block boundary discontinuities.
Importantly, all current art methods appear to achieve blocking artifact reduction by in one fashion or another performing versions of spatial low-pass filtering. These current art methods also all suffer from one or more additional problems, such as producing overall image degradation, limiting image compression, failing to explicitly address the perceptual aspects of blocking artifacts, requiring excessive computational resources, and so forth.
What is needed, therefore, is a method and system for post-processing decompressed images which is computationally efficient, avoids spatial low-pass filtering, does not produce image degradation, has no effect on compression, and, most importantly, minimizes the perceptual aspects of blocking artifacts.
Citation of a reference herein, or throughout this specification, is not to construed as an admission that such reference is prior art to the Applicant's invention of the invention subsequently claimed.
SUMMARY OF THE INVENTION
The objects of the present invention are to provide systems and methods for post-processing decompressed images in order to minimize blocking artifacts and which overcome the above identified problems in the current art.
Fundamentally, these objects are achieved by methods which achieve blocking artifact reduction by correcting the surface defined by the pixel values in a block of pixels with “bending”, “tilting”, or “twisting” deformations in order to more closely match pixel-value surfaces of adjoining pixel blocks. Since low-pass filtering is avoided by such surface deformations, the corrections added to the pixel values by the methods of this invention more closely match the actual errors and artifacts introduced by the image blocking process.
In detail, these objects are achieved by determining an 8×8 matrix of correction values for each processed 8×8 pixel block in an image. The correction matrices are then added to the pixel blocks in order to derive post-processed pixel blocks with minimized blocking artifacts. The resulting pixel values of the corrected pixel blocks blend with pixel values of adjacent blocks, also typically corrected, in a perceptually smooth manner with minimum block-to-block artifacts. The correction matrices are derived from differences between values of pixels along the edges of a block to be post-processed and pixels along the edges of the four orthogonally adjacent pixel blocks. Alternatively, the correction matrix is derived from zero-frequency (“DC”) transform coefficients of a pixel block to be post-processed and the four adjacent pixel blocks.
The 8×8 matrix of correction values is either derived directly according to a preferred entirely spatial-domain interpolation, or derived indirectly by an alternative computation from a smaller 4×4 spatial-domain intermediary error correction matrix. Direct and inverse transforms of the intermediary correction matrix to and back from a frequency domain accomplish smooth interpolation of the smaller intermediary matrix to an 8×8 matrix of correction values. Preferably, decoded blocks are selected for post-processing principally in relatively flat or featureless image regions. Such image regions are most likely to have perceptually apparent blocking artifacts.
In detail, these objects are achieved by the following embodiments of this invention. In a first embodiment, the present invention includes a method for post-processing a decompressed image, the image having been compressed by a process including independent compression of non-overlapping rectangular blocks of pixels covering the original image, the method comprising: determining four or more quantities for each pixel block in the decompressed image that are representative of blocking artifacts, wherein the four or more quantities for a pixel block are determined from block-to-block differences between combinations of values of pixels in that pixel block and combinations of values of pixels in the four pixel blocks orthogonally adjacent to that pixel block, selecting pixel blocks for post-processing according to the four or more quantities for each pixel block and a threshold value, determining an error correction matrix for each selected pixel block from the four or more quantities for that selected pixel block, wherein the error correction matrices have the same size as the pixel blocks, and adding the error correction matrices to the selected pixel blocks to derive post-processed pixel blocks and the post-processed image.
In a first aspect of the first embodiment, the four or more quantities for a pixel block are four quantities determined from the four differences between averages of values of pixels along each edge of that pixel block and averages of values of pixels along adjacent edges of the adjacent pixel blocks.
In a second aspect of the first embodiment, the four or more quantities for a pixel block are determined from averages of differences between the values of pixels of each of two or more adjacent pairs of pixels, and for each pair of pixels one pixel of that pair is at an edge of that pixel block and the other pixel of that pair is adjacent at an adjacent edge of the adjacent pixel block.
In a third aspect of the first embodiment, compression of a pixel block comprises quantizing transform coefficients of the values of pixel of that pixel block. Additionally in this aspect the four or more quantities for a pixel block are four quantities determined from the four differences between a zero-frequency (DC) transform coefficient of that pixel block and zero-frequency transform coefficients of the four orthogonally adjacent pixel blocks. Additionally in this aspect the threshold value is of the order of magnitude of errors in pixel values introduced by the combined steps of transforming, quantizing, dequantizing, and inverse transforming applied to pixel blocks.
In a fourth aspect of the first embodiment, each error correction matrix is determined by a process comprising linearly interpolating the four or more quantities according to selected spatial configuration weights in order to determine elements of the error correction matrices.
Additionally in this aspect, the linear interpolation is performed in a dimensionally-independent manner according to which a quantity at an edge is interpolated similarly to all error correction matrix elements that are in a direction perpendicular to that edge. Additionally in this aspect, the spatial configuration weights are selected such that (i) the largest weight is applied at the edge associated with the quantity to be interpolated, (ii) the sum of the spatial configuration weights is zero, and (iii) the interpolation of equal quantities of opposite sign at two opposite edges result in a linear gradient of error correction matrix elements between the two opposite edges.
In a fifth aspect of the first embodiment, determining an error correction matrix comprises: determining an intermediary error correction matrix having a size smaller than the size of the pixel blocks by linearly interpolating the four or more quantities in a dimensionally independent manner according to selected spatial configuration weights, transforming the intermediary error correction matrix to a transform domain, and inverse transforming the transformed intermediary error correction matrix to the error correction matrix, wherein for the inverse transformation selected higher order transform coefficients are set to zero. Additionally in this aspect, the pixel blocks are square of size 8×8 pixels, and the intermediary error correction matrices are square of size 4×4 pixels.
In a sixth aspect of the first embodiment, the error correction matrix is determined so that block-to-block pixel differences between two adjacent post-processed pixel blocks are smaller than but of the same sign as the block-to-block pixel differences between those two adjacent pixel blocks prior to post-processing.
In a second embodiment, the present invention includes a computer readable media encoded with program instructions for causing one or more processors to perform the methods and the aspects of the methods of the first embodiment.
In a third embodiment, the present invention includes a system for post-processing a decompressed image, the image having been compressed by a process including independent compression of non-overlapping rectangular blocks of pixels covering the original image, the system comprising: means for determining four or more quantities for each pixel block in the decompressed image that are representative of blocking artifacts, wherein the four or more quantities for a pixel block are determined from block-to-block differences between combinations of values of pixels in that pixel block and combinations of values of pixels in the four pixel blocks orthogonally adjacent to that pixel block, means for selecting pixel blocks for post-processing according to the four or more quantities for each pixel block and a threshold value, means for determining an error correction matrix for each selected pixel block from the four or more quantities for that selected pixel block, wherein the error correction matrices have the same size as the pixel blocks, and means for adding the error correction matrices to the selected pixel blocks to derive post-processed pixel blocks and the post-processed image.
In a fourth embodiment, the present invention includes a system for post-processing a decompressed image, the image having been compressed by a process including independent compression of non-overlapping rectangular blocks of pixels covering the original image, the system comprising: one or more processors for executing program instructions, and one or more memory units for storing an image to be processed and program instructions, wherein the program instructions cause the one or more processors to determine four or more quantities for each pixel block in the decompressed image that are representative of blocking artifacts, wherein the four or more quantities for a pixel block are determined from block-to-block differences between combinations of values of pixels in that pixel block and combinations of values of pixels in the four pixel blocks orthogonally adjacent to that pixel block, to select pixel blocks for post-processing according to the four or more quantities for each pixel block and a threshold value, to determine an error correction matrix for each selected pixel block from the four or more quantities for that selected pixel block, wherein the error correction matrices have the same size as the pixel blocks, and to-add the error correction matrices to the selected pixel blocks to derive post-processed pixel blocks and the post-processed image.
BRIEF DESCRIPTION OF THE DRAWING
Other objects, features and advantages of the present invention will become apparent upon perusal of the following detailed description when taken in conjunction with the appended drawing, wherein:
FIGS. 1A-B illustrate exemplary embodiments of systems of the present invention;
FIGS. 2A-B illustrate exemplary pixel blocks;
FIG. 3 illustrates exemplary embodiments of methods of the present invention;
FIGS. 4A-D illustrate exemplary spatial weighting configurations;
FIG. 5 illustrates a test image;
FIG. 6 illustrates the test image of FIG. 5 with a maximum of blocking artifacts; and
FIG. 7 illustrates the result of post-processing the image of FIG. 6 according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following, exemplary embodiments of systems of the present invention are first described followed by detailed descriptions of embodiments of the methods of the present invention. Finally, an example of applying an embodiment of the present invention to a test image with a maximum of blocking artifacts is presented.
Preferred Systems Embodiments
FIG. 1A generally illustrates an embodiment of a system according to the present invention, represented within box 4 , in conjunction with a conventional image decoder system, including input 1 , decoder 2 , and image buffer 3 .
The present invention is adaptable to decoded images that were encoded by any process that divides an original image into non-overlapping, rectangular blocks of pixels, and independently encodes each such rectangular block. In the following, the invention is described with respect to such conventional families of compression standards as JPEG, MPEG, and H.320, according to which an original image is divided into non-overlapping and independent 8×8 blocks of pixels, which are encoded as quantized DCT coefficients.
The invention is most effective when the images are highly compressed, and, accordingly, when quantization of the DCT coefficients is aggressive or coarse. Exemplary of such compression levels is compression to 0.25 or less bits of luminance information per pixel.
Encoded images are input at 1 to the conventional decoder system illustrated. Decoder 2 then performs conventional decoding of the input images according to the encoding method, and stores decoded images temporarily in image buffer 3 . In the absence of the present invention, the images are directly output from the image buffer. The present invention adds the processing elements and steps represented within box 4 to such a conventional decoder.
The general processing operations performed by the present invention are next generally described with details following subsequently. In first processing operation 5 , quantities representative of blocking artifacts in a decoded or decompressed image, are determined for all blocks from various aspects block-to-block pixel value differences. Preferably, four such representative quantities are determined for each pixel block. In second processing operation 6 , the individual blocks to be post-processed by the present invention are selected heuristically in view of the determined block-to-block differences. In one embodiment, if any of these differences exceed a threshold value, the block is not processed; alternatively, if the differences exceed the threshold, their values are set down to that threshold. This-step reflects the discovery of the inventor that large block-to-block differences are likely caused by structure actually present in the original image, while small block-to-block differences typically reflect blocking artifacts present in relatively featureless regions on the original image. These should be corrected. Finally, in third processing operation 7 , for each post-processed 8×8 block, an 8×8 matrix of correction values is determined according to the alternative embodiments to be described subsequently. The correction values are determined to smoothly link the post-processed block to its orthogonally-adjacent blocks Processing of the blocks in the image buffer can be sequential or in parallel according to the available hardware.
Finally, the correction matrix and the original decoded block are added by adder 8 and stored back in image buffer 3 . When all blocks in the image buffer have been processed, a corrected image with minimal blocking artifacts is output at 10 .
Optionally, the DC coefficients (i.e., zero frequency coefficients) transmitted in the encoded images can be used in processing step 5 to determine the block-to-block differences. In this case, it is advantageous for the decoder to make these coefficients available over connection 9 , which can include a coefficient buffer as needed.
This system can be implemented in various hardware configurations that will be apparent to one of average skill. For example, the individual image processing operations represented in FIG. 1A can be implemented with individually dedicated hardware components. However, it is currently preferable that the processing operations of the system be implemented by one or more special software routines running on general purpose hardware, perhaps optimized for image decoding, such as that illustrated in FIG. 1 B. FIG. 1B illustrates one or more processors 11 for decoding images and performing the operations of the present invention, one of more RAM modules 12 for storing image data and/or program instructions, optionally one or more ROM modules 13 for storing program instructions, one or more I/O interface devices 14 for communicating with other systems, and one or more busses 15 for connecting these individual components. Advantageously, the processors include one or more digital signal processors (“DSP”), such as the TM-1000 type DSP (Philips Electronics North America Corp.) or the TMS-3000 type DSP (Texas Instruments, Inc.).
In the preferred embodiment where the system processing operations are implemented in software, the present invention further comprises computer readable media on which are recorded or encoded program instructions for causing processors to perform the processing operation of the system. Such media can include magnetic media, such as floppy discs, hard discs, tapes, and so forth, optical media, such as CD-ROMS, and other media technologies usable in the art.
Preferred Method Embodiments
Preferred and alternative embodiments of processing operations 5 - 7 (FIG. 1A) are next described in detail. First, determination of block-to-block pixel differences, processing operation 5 (FIG. 3 ), which according to the present invention are taken to be representative of blocking artifacts, is described with reference to the candidate pixel blocks illustrated in FIGS. 2A-B. Although these figures and the subsequent discussion treats the common case of 8×8 pixel blocks, one of average skill will immediately appreciate how to modify the methods to be described in case rectangular pixel blocks of sizes other than 8×8 are used in a particular compression method.
For candidate, central pixel block C in FIG. 2A, block-to-block pixel differences are determined with respect to the four, orthogonally-adjacent pixel blocks sharing edges with candidate, central block C. These blocks are labeled W (to the west of C), N (to the north of C), E (to the east of C), and S (to the south of C) in FIG. 2 A. Diagonally adjacent pixel blocks are not directly considered. FIG. 2B illustrates pixel blocks C, N, E, W, and S in more detail in the case where the relevant image compression methods use 8×8 pixel blocks. Edge pixels for all these blocks are indicated in standard matrix notation. Also indicated are the DC coefficients (zero frequency coefficients) for these blocks (C DC , N DC , E DC , W DC , S DC ). It is well known that the DC coefficients are simply averages of the values of all the pixels in a block, and may be obtained directly from decoder 2 or may be computed as part of step 5 .
With reference to FIG. 2B, a first method for determining block-to-block pixel differences computes the average differences between pixels along each edge of block C and pixels along adjacent edges of blocks N, E, W, and S. Four quantities are returned, each reflecting the block-to-block differences along an edge of central block C. This preferred method, directly and with minimum computation, returns values representative of pixel-value discontinuities at the boundaries of a pixel block. The following equations are representative of this method, where the four quantities N, E, W, and S are average edge-adjacent pixel differences along the north, east, west, and south edges of central block C, respectively. N = 0.125 * FA * { ( N 70 + N 71 + N 72 + N 73 + N 74 + N 75 + N 76 + N 77 ) - ( C 00 + C 01 + C 02 + C 03 + C 04 + C 05 + C 06 + C 07 ) } E = 0.125 * FA * { ( E 00 + E 10 + E 20 + E 30 + E 40 + E 50 + E 60 + E 70 ) - ( C 07 + C 17 + C 27 + C 37 + C 47 + C 57 + C 67 + C 77 ) } W = 0.125 * FA * { ( W 07 + W 17 + W 27 + W 37 + W 47 + W 57 + W 67 + W 77 ) - ( C 00 + C 10 + C 20 + C 30 + C 40 + C 50 + C 60 + C 70 ) } S = 0.125 * FA * { ( S 00 + S 01 + S 02 + S 03 + S 04 + S 05 + S 06 + S 07 ) - ( C 70 + C 71 + C 72 + C 73 + C 74 + C 75 + C 76 + C 77 ) }
Factor FA is a multiplicative weighting factor for scaling these edge differences. It is described subsequently in more detail in conjunction with second weighting factor FB.
A second alternative method for determining block-to block pixel differences employs DC coefficients, where available. This method returns four quantities representative of the differences in average intensity between central block C and its four orthogonally-adjacent surrounding blocks, N, E, W, and S. The following equations are representative of this method.
N=FA*{N DC −C DC }; E=FA*{E DC −C DC }
W=FA*{W DC −C DC }; S=FA*{S DC −C DC }
Finally, a third alternative method captures increased detail of block-to-block pixel differences along block edges by computing sub-edge differences. The methods above, which determine only four quantities, one for each edge of a central block, necessarily represent, therefore, only average differences along an entire edge. However, perceptual blocking artifacts can also reflect variations in block-to-block pixel differences along each edge, as well as simply block-to-block average differences. The third alternative method captures such variations in intensity by computing more than one quantity for each edge, each quantity representing the differences in one or more pairs of edge-adjacent pixels of central block C, instead of merely the average of all pixels along an edge. In a case where averages of the differences of two adjacent pairs of pixels are computed, the following equations are representative of the third alternative.
A=0.250*FA*{(W 17 −C 10 )+(W 07 −C 00 )+(N 70 −C 00 )+(N 71 −C 01 )}
B=0.500*FA*{(N 72 −C 02 )+(N 73 −C 03 )}
C=0.500*FA*{(N 74 −C 04 )+(N 75 −C 05 )}
D=0.250*FA*{(N 76 −C 06 )+(N 77 −C 07 )+(E 00 −C 07 )+(E 01 −C 17 )}
E=0.500*FA*{(E 20 −C 27 )+(E 30 −C 37 )}
F=0.500*FA*{(E 40 −C 47 )+(E 50 −C 57 )}
G=0.250*FA*{(E 60 −C 67 )+(E 70 −C 77 )+(S 07 −C 77 )+(S 06 −C 76 )}
H=0.500*FA*{(S 05 −C 75 )+(S 04 −C 74 )}
I=0.500*FA*{(S 03 −C 73 )+(S 02 −C 72 )}
J=0.250*FA*{(S 01 −C 71 )+(S 00 −C 70 )+(W 77 −C 70 )+(W 67 −C 60 )}
K=0.500*FA*{(W 57 −C 50 )+(W 47 −C 40 )}
L=0.500*FA*{(W 37 −C 30 )+(W 27 −C 20 )}
For illustrative purposes, quantities J, I, H, and G represent differences between pair of pixels in the outlined sub-blocks 16 , 17 , 18 , and 19 , respectively. Of course, a finer representation could be used, for example one in which a quantity is computed from the difference of each pair of edge-adjacent Pixels. Alternately, a coarser representation could be used by combining certain of the above quantities. For example, the following combined and coarser quantities can be used.
B′=C′=0.500*(B+C); E′=F′=0.500*(E+F)
I′=H′=0.500*(I+H); L′=K′=0.500*(L+K)
Other similar alternatives of increased or decreased coarseness will be apparent to one of skill in the art.
Turning to the next processing operation, operation 6 of FIG. 3, blocks are selected for post-processing in view of heuristic block selection criteria that depend on the block-to-block pixel differences determined above. The overall goal and purpose of the system and method of the present invention is to achieve perceptually improved images, and not to post-process images merely to achieve certain mathematical effects or consistency without regard to perceptual changes. Accordingly, the methods of the present invention include heuristic block selection criteria, adjustable weighting factors for block-to-block pixel differences, and computational alternatives that can be adjusted or selected in particular cases to obtain maximum perceptual improvements, in general or with respect to image classes or interest, within the processing resources available.
In detail, block selection criteria are derived from the discovery of the inventor that in many cases block-to-block pixel differences represent image structures in a source image whose correction can result in perceptually objectionable image alterations. Such differences are likely to represent real image structure where the differences along one or more edges are particularly “large”. In contrast, where block-to-block differences are “small”, the actual image is likely to be relatively flat or featureless, i.e., devoid of particularly apparent structure. In such regions small blocking artifacts are most perceptually apparent, and, therefore, should be corrected according to the present invention. Additionally, “small” block-to-block pixel difference are also a likely indicator of differences due only to blocking artifacts. “Small” is advantageously measured in view of a particular image compression algorithm as that degree of block-to-block pixel differences which are of a magnitude likely to be due to quantization errors in the low frequency transform coefficients, in particular as that degree of block-to-block pixel differences resulting from zeroing of low frequency transform coefficients as a result of coarse quantization and subsequent dequantization. A “small” difference is taken to be of the magnitude of this quantization error, or in other words preferably approximately 2-4 times such quantization error. A “large” block-to-block pixel difference, on the other hand, is preferably 5 or more times such quantization error. Therefore, block with “small” block-to-block pixel differences are post-processed, while block with large differences are not.
In particular, for JPEG or MPEG, which use DCT transformation of 8×8 blocks, applied to pixels represented by 8 bits (values between 0 and 255), “small” is preferably a block-to-block difference of less than 5, and more preferably less than 2. A large difference is preferably 6, or more preferably 8, or more. Exact values are advantageously selected to achieve the maximum perceptual improvement.
In a preferred block selection criterion, any pixel block having any block-to-block difference with an adjacent block which is greater than the selected threshold is not processed. Alternatively, all blocks can be processed but any block-to-block difference exceeding the selected threshold value is set back to and limited by the threshold value. This latter alternative is advantageous in order to correct blocks with one side bordering actual image structure and another side bordering flat or featureless image regions.
In a further alternative, where all transform coefficients are available from a decoder, blocks with little AC (non-zero frequency) energy (determined, for example, as the sum of the squares of the transform coefficients) are chosen for processing. For example, blocks with no more than 5%, or more preferably no more than 3%, of their energy in the AC terms are selected for processing.
For the blocks selected in processing operation 6 and using the block-to-block pixel differences determined in processing operation 5 , processing operation 7 (FIG. 1A) next determines matrices of error correction values which are added to the processed blocks by adder 8 to finally arrive at corrected blocks. The error correction matrices are the same size as the pixel blocks. Corrected images result from processing all pixel blocks in the images. FIG. 3 illustrates processing operation 7 in more detail as having two principal alternatives, preferred operation 7 ′ and alternative operation 7 ″. Generally, according to preferred operation 7 ′, the block-to-block pixel differences are directly converted into an 8×8 (or other size) error correction matrix. According to alternative operation 7 ″, the differences are first converted into a 4×4 intermediate error matrix, which is then smoothly expanded into a final 8×8 error correction matrix by a transform and inverse transform.
In more detail, preferred operation 7 ′ interpolates the error correction matrix elements from the block-to-block pixel differences determined along each edge. This interpolation is done in a dimension independent manner, in that each matrix element has independent, weighted contributions from each determined block-to-block pixel difference, and each determined block-to-block pixel difference contributes independently only to matrix elements in that row or column of that particular pixel difference.
For example, in case of a value representing the average difference of edge-adjacent pixels along an entire edge, the value is interpolated along all rows or columns perpendicular to that edge.
The weights of the pixel differences have chosen a spatial configuration and a selected overall multiplicative weight, FA*FB. The spatial configuration is chosen, limited by constraints, in order to result in a maximum perceptual improvement. One constraint is that the maximum spatial weight occur adjacent to the block edge of that block-to-block difference to be interpolated. Another constraint is that the sum of the weights be zero in order that the average brightness of the pixel block does not change. A final heuristic constraint is that a difference at one edge of a pixel block coupled with another difference of the same size but different sign at the opposite edge (along a row or column) should interpolate to a uniform gradient between the two edges.
FIG. 4C illustrates the spatial configuration weights for creating the 8×8 error correction matrix of the preferred alternative. The maximum weight occurs next to the interpolated block-to-block pixel difference. The sum of the weights is clearly-zero. Finally, a unit positive pixel difference at a left edge together with a unit negative pixel difference at a right edge is interpolated by the spatial configuration of FIG. 4C into the preferred linear gradient of FIG. 4 D. One of average skill will understand how to expand or compress this preferred spatial configuration for other pixel array sizes.
The overall multiplicative factor, FA*FB, is also selected, limited by constraints, in order to result in a maximum perceptual improvement. The overall factor is divided between a weight factor for the block-to-block pixel difference, FA, and a weight factor for the error correction matrix, FB. According to one constraint, the overall factor, FA*FB, is less then or equal 0.500 so that edges between adjacent corrected pixel blocks are not over corrected, that is so that corrected pixel blocks have their block-to-block edge differences reduced without changing the direction of that edge difference. According to another overlapping constraint, the overall factor is less than 0.500 because, in the presence of pixel-value gradients, a certain block-to-block edge difference can be an actual image feature and should not be eliminated. There is also a weighting factor present for normalizing the maximum of the spatial configuration weights to 1.00.
In preferred embodiments, FA is taken as 1.0, so that the block-to-block pixel differences represent unscaled pixel values. Second, FB is advantageously taken as 0.375 as this factor gives good perceptual results and is rapid to compute by shifts and additions without multiplications.
Accordingly, in a preferred embodiment of processing operation 7 ′, the error correction matrix is interpolated from four block-to-block pixel differences, one for each edge of the pixel block to be post-processed, according to the following equations, where FA=1.0 in the determination of the N, E, W, and S differences and FB=0.375*(1.0/4.0). (1/0/4.0 is the spatial configuration weight normalization factor.) The N, E, W, and S input difference values are preferably determined as the average differences of edge-adjacent pixels described above, or alternative as the difference in the DC coefficients, also described above. The following equations defining this matrix are exemplary. matrix [ 0 ] [ 0 ] = FB * { 4 * N + 4 * W } matrix [ 0 ] [ 1 ] = FB * { 4 * N - E + 2 * W } matrix [ 0 ] [ 2 ] = FB * { 4 * N - 2 * E } matrix [ 0 ] [ 3 ] = FB * { 4 * N - 2 * E - W } matrix [ 0 ] [ 4 ] = FB * { 4 * N - E - 2 * W } matrix [ 0 ] [ 5 ] = FB * { 4 * N - 2 * W } matrix [ 0 ] [ 6 ] = FB * { 4 * N + 2 * E - W } matrix [ 0 ] [ 7 ] = FB * { 4 * N + 4 * E } matrix [ 1 ] [ 0 ] = FB * { 2 * N + 4 * W - S } matrix [ 1 ] [ 1 ] = FB * { 2 * N - E + 2 * W - S } matrix [ 1 ] [ 2 ] = FB * { 2 * N - 2 * E - S } matrix [ 1 ] [ 3 ] = FB * { 2 * N - 2 * E - W - S } matrix [ 1 ] [ 4 ] = FB * { 2 * N - E - 2 * W - S } matrix [ 1 ] [ 5 ] = FB * { 2 * N - 2 * W - S } matrix [ 1 ] [ 6 ] = FB * { 2 * N + 2 * E - W - S } matrix [ 1 ] [ 7 ] = FB * { 2 * N + 4 * E - S } matrix [ 2 ] [ 0 ] = FB * { + 4 * W - 2 * S } matrix [ 2 ] [ 1 ] = FB * { - E + 2 * W - 2 * S } matrix [ 2 ] [ 2 ] = FB * { - 2 * E - 2 * S } matrix [ 2 ] [ 3 ] = FB * { - 2 * E - W - 2 * S } matrix [ 2 ] [ 4 ] = FB * { - E - 2 * W - 2 * S } matrix [ 2 ] [ 5 ] = FB * { - 2 * W - 2 * S } matrix [ 2 ] [ 6 ] = FB * { + 2 * E - W - 2 * S } matrix [ 2 ] [ 7 ] = FB * { + 4 * E - 2 * S } matrix [ 3 ] [ 0 ] = FB * { - N + 4 * W - 2 * S } matrix [ 3 ] [ 1 ] = FB * { - N - E + 2 * W - 2 * S } matrix [ 3 ] [ 2 ] = FB * { - N - 2 * E - 2 * S } matrix [ 3 ] [ 3 ] = FB * { - N - 2 * E - W - 2 * S } matrix [ 3 ] [ 4 ] = FB * { - N - E - 2 * W - 2 * S } matrix [ 3 ] [ 5 ] = FB * { - N - 2 * W - 2 * S } matrix [ 3 ] [ 6 ] = FB * { - N + 2 * E - W - 2 * S } matrix [ 3 ] [ 7 ] = FB * { - N + 4 * E - 2 * S } matrix [ 4 ] [ 0 ] = FB * { - 2 * N + 4 * W - S } matrix [ 4 ] [ 1 ] = FB * { - 2 * N - E + 2 * W - S } matrix [ 4 ] [ 2 ] = FB * { - 2 * N - 2 * E - S } matrix [ 4 ] [ 3 ] = FB * { - 2 * N - 2 * E - W - S } matrix [ 4 ] [ 4 ] = FB * { - 2 * N - E - 2 * W - S } matrix [ 4 ] [ 5 ] = FB * { - 2 * N - 2 * W - S } matrix [ 4 ] [ 6 ] = FB * { - 2 * N + 2 * E - W - S } matrix [ 4 ] [ 7 ] = FB * { - 2 * N + 4 * E - S } matrix [ 5 ] [ 0 ] = FB * { - 2 * N + 4 * W } matrix [ 5 ] [ 1 ] = FB * { - 2 * N - E + 2 * W } matrix [ 5 ] [ 2 ] = FB * { - 2 * N - 2 * E } matrix [ 5 ] [ 3 ] = FB * { - 2 * N - 2 * E - W } matrix [ 5 ] [ 4 ] = FB * { - 2 * N - E - 2 * W } matrix [ 5 ] [ 5 ] = FB * { - 2 * N - 2 * W } matrix [ 5 ] [ 6 ] = FB * { - 2 * N + 2 * E - W } matrix [ 5 ] [ 7 ] = FB * { - 2 * N + 4 * E } matrix [ 6 ] [ 0 ] = FB * { - N + 4 * W + 2 * S } matrix [ 6 ] [ 1 ] = FB * { - N - E + 2 * W + 2 * S } matrix [ 6 ] [ 2 ] = FB * { - N - 2 * E + 2 * S } matrix [ 6 ] [ 3 ] = FB * { - N - 2 * E - W + 2 * S } matrix [ 6 ] [ 4 ] = FB * { - N - E - 2 * W + 2 * S } matrix [ 6 ] [ 5 ] = FB * { - N - 2 * W + 2 * S } matrix [ 6 ] [ 6 ] = FB * { - N + 2 * E - W + 2 * S } matrix [ 6 ] [ 7 ] = FB * { - N + 4 * E + 2 * S } matrix [ 7 ] [ 0 ] = FB * { + 4 * W + 4 * S } matrix [ 7 ] [ 1 ] = FB * { - E + 2 * W + 4 * S } matrix [ 7 ] [ 2 ] = FB * { - 2 * E + 4 * S } matrix [ 7 ] [ 3 ] = FB * { - 2 * E - W + 4 * S } matrix [ 7 ] [ 4 ] = FB * { - E - 2 * W + 4 * S } matrix [ 7 ] [ 5 ] = FB * { - 2 * W + 4 * S } matrix [ 7 ] [ 6 ] = FB * { + 2 * E - W + 4 * S } matrix [ 7 ] [ 7 ] = FB * { + 4 * E + 4 * S }
The output is the 8×8 error correction matrix.
It will be apparent how to alter these equations where any pixel block edge is associated with more that a single block-to-block pixel difference parameter.
Turning to the alternative embodiment, generally this embodiment determines an error correction matrix which has a size that is smaller than the size of a pixel block and then expands this smaller error correction matrix to the size of the pixel block. The smaller error correction matrix preferably has a size that is a rational fraction of the size of the pixel block, e.g., a 4×4 size when the pixel block size is 8×8. The smaller error correction matrix is preferably expanded in a smooth fashion. For example, this expansion can be done by transforming to a transform domain followed by inverse transforming, with higher frequency coefficients set to zero, from that transform domain to a matrix the size of a pixel block.
In more detail, this alternative embodiment, processing operation 7 ″ of FIG. 3, is illustrated as commencing with operation 20, determination of a 4×4 error matrix. In a preferred embodiment of this alternative method, this 4×4 matrix is determined similarly to the 8×8 matrix discussed above, that is matrix elements are interpolated from the block-to-block pixel differences determined along each edge in a dimension independent manner, such that each matrix element has independent, weighted contributions from each perpendicularly-related block-to-block pixel difference. These pixel differences weights also have a chosen spatial configuration and a selected overall multiplicative weight, FA*FB. The spatial configuration is preferably chosen according to the principles discussed above. FIG. 4A illustrates a preferred spatial weight configuration having elements that sum to zero and which results in a linear gradient between equal but opposite differences at each edge of the 4×4 matrix, as illustrated in FIG. 4 B. The multiplicative weights are preferably selected as discussed above. Therefore, it is again preferred that FA=1.0 and FB=0.375. Again, the N, E, W, and S input block-to-block pixel differences are preferably determined as the average differences of edge-adjacent pixels described above, or alternative as the differences in the DC coefficients, also described above.
The following equations are exemplary of this preferred embodiment for defining the 4×4 matrix. FB equals 0.375 multiplied by 1.0/3.0, the spatial configuration normalization factor. matrix [ 0 ] [ 0 ] = FB * { 3 * N + 3 * W } matrix [ 0 ] [ 1 ] = FB * { 3 * N - W - 2 * E } matrix [ 0 ] [ 2 ] = FB * { 3 * N - 2 * W - E } matrix [ 0 ] [ 3 ] = FB * { 3 * N + 3 * E } matrix [ 1 ] [ 0 ] = FB * { - N - 2 * S + 3 * W } matrix [ 1 ] [ 1 ] = FB * { - N - 2 * S - W - 2 * E } matrix [ 1 ] [ 2 ] = FB * { - N - 2 * S - 2 * W - E } matrix [ 1 ] [ 3 ] = FB * { - N - 2 * S + 3 * E } matrix [ 2 ] [ 0 ] = FB * { - 2 * N - S + 3 * W } matrix [ 2 ] [ 1 ] = FB * { - 2 * N - S - W - 2 * E } matrix [ 2 ] [ 2 ] = FB * { - 2 * N - S - 2 * W - E } matrix [ 2 ] [ 3 ] = FB * { - 2 * N - S + 3 * E } matrix [ 3 ] [ 0 ] = FB * { + 3 * S + 3 * W } matrix [ 3 ] [ 1 ] = FB * { + 3 * S - W - 2 * E } matrix [ 3 ] [ 2 ] = FB * { + 3 * S - 2 * W - E } matrix [ 3 ] [ 3 ] = FB * { + 3 * S + 3 * E }
In another embodiment, this 4×4 matrix can be determined from pixel sub-edge differences, which reflect finer structure of the block-to-block pixel differences along an edge. Exemplary of such sub-edge differences are the quantities A-L discussed above. In one alternative, these sub-edge difference can be placed around the edges of the 4×4 matrix., one sub-edge difference being placed in the 4×4 matrix at a position corresponding to the position of original pixels in the original 8×8 matrix. The central four matrix elements can be set to zero. The following equations are representative of this alternative, with FB being preferably 0.375.
matrix[0][0]=FB*A; matrix [0][1]=FB*B; matrix [0][2]=FB*C;
matrix[0][3]=FB*D; matrix [1][3]=FB*E; matrix [2][3]=FB*F;
matrix[3][3]=FB*G; matrix [3][2]=FB*H; matrix [3][1]=FB*I;
matrix[3][0]=FB*J; matrix [2][0]=FB*K; matrix [1][0]=FB*L;
matrix[1][1]=matrix[1][2]=matrix[2][1]=matrix[2][2]=0.0
Alternatively, the inner four matrix elements interpolated from the edge elements in a dimension independent manner using the spatial configuration weights of FIG. 4 A.
The next processing operations of alternative 7 ″ expand the 4×4 matrix into an 8×8 matrix in a smooth manner, that is introducing only a minimum of higher spatial frequency components into the final 8×8 matrix. In step 21 , the 4×4 matrix is transformed into a 4×4 matrix in a suitable frequency domain. A DCT transform is preferred, but this invention is adaptable to other transforms, such as the computationally inexpensive Hadamard transform. In step 22 , the 4×4 frequency domain matrix is embedded in an 8×8 frequency domain matrix with all the remaining elements set to 0. Alternatively, certain elements in the 4×4 matrix, such as the bottom-most row and right-most column, may also be set to zero. Thereby the higher frequency components represented by these matrix elements are zero. Finally, in step 23 , the 8×8 frequency domain matrix is inverse transformed into an 8×8 spatial domain error correction matrix, which is used in the subsequent steps of this invention just as the 8×8 matrix of the preferred alternative is used. Preferably, the inverse transform is the same as the forward transform, that is an inverse DCT is used in step 23 if a DCT is used in step 21 .
The 8×8 error correction matrix resulting from either the preferred embodiment or the alternative embodiment is then added to the original pixel block to result in a pixel block corrected for blocking artifacts. This process is repeated for all pixel blocks in the image in order to derive a corrected image.
It will be apparent-that, for various classes of images and particular compression methods, the parameters of this method, in particular the block selection threshold and the overall weighting factor values, can be optimized to give maximum perceptual improvement.
Further, the equations presented above are exemplary of one embodiment of the methods described. One of skill in the art will immediately appreciate how their form could be improved for computational efficiency in micro-processors and digital signal processors of various architectures. For example, the total number of arithmetic operations can be reduced by factorization in view of the dimension independence of the 8×8 and 4×4 matrices. Further, multiplicative operations, including the overall multiplicative weight factor, can be implemented by less costly shifts and additions, instead of more costly multiplications.
Additionally, the particular combination of alternatives chosen from those described above can be dictated by a tradeoff of the processing power available in a system with the degree of perceptual improvement sought. This invention is adaptable to a range of degrees of perceptual improvement as increased processing power is available.
It should now be appreciated that the objects of the present invention are satisfied. While the present invention has been described in particular detail, it should also be appreciated that numerous modifications are possible and will be apparent to one of average skill in the art. These modifications are intended to be within the spirit and scope of the invention as claimed.
EXAMPLE
An example of the functioning of an alternative embodiment of the present invention is described herein. FIG. 5 is a 640×480 test image created by expanding each pixel of a 320×240 monochrome source image to four identical neighboring pixels. The source image has a luminance varying between 64 and 192 in a total range of 0 to 255 according to the following equations.
luminance=128+(64−4R)*cos(4R)
R=(radius in pixel widths/40) 1.5
FIG. 6 is a DCT transform of this image with all DCT coefficients set to zero except for the DC coefficients. It represents a maximally compressed version of FIG. 5 having a maximum of blocking artifacts. Each 8×8 pixel block is clearly apparent.
FIG. 7 is a version of FIG. 6 post-processed according to the following early embodiment of the present invention. Sub-edge pixel differences A-L were determined as discussed above, resulting in four block-to-block pixel differences for each edge of each 8×8 pixel block. These coefficients were placed appropriately around the edge of a 4×4 matrix, as described for an alternative embodiment of processing operation 7 ″, and were then Hadamard transformed. The overall weighting factor was 0.125, a very conservative value compared to the preferred value of 0.375. The upper left hand 3×3 sub-matrix (out of the total 4×4 matrix) of Hadamard coefficients, together with the original DC coefficient, were inverse DCT transformed to derive FIG. 7 .
FIG. 7 is certainly perceptually much improved, the extreme blocking artifacts being much reduced and even eliminated in the central regions of the image.
The example illustrates the power of the system and method of this invention to achieve substantial reduction in blocking artifacts of image compression algorithms by using only simple and computationally inexpensive processing operations.
All references cited herein are incorporated herein by reference in their entirety and for all purposes to the same extent as if each individual publication or patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety for all purposes. | This invention relates to a system and method for reducing blocking artifacts introduced by current compression algorithms that compress images as independent blocks of pixels. Preferably, the methods of the invention include determining block-to-block differences in edge pixels or in overall intensities between adjacent pixel blocks, selecting pixel blocks for post-processing that appear to be in relatively featureless regions of the image, interpolating the block-to-block edge differences into a error correction matrix, and then subtracting the error correction matrix from the original pixel block. These methods are preferably implemented in special software routines that execute on micro-processor based systems or on digital signal processor based systems optimized for image decoding. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the recording of data onto optical media, and more specifically to a method for more efficiently processing data files selected for recording to an optical media.
2. Description of the Related Art
The storage of data to optical media has gradually, but steadily, increased in popularity and frequency of use. A typical consumer computer owner and operator counts a re-writable compact disc, or other optical media, drive among standard equipment for the home or office computer system. As the use of optical media continues to grow, so too does the demand for faster and less complicated recording applications and processes.
As is known, the process for recording data to an optical media generally includes the selection of data files to be recorded, also known as “burned,” to an optical media, the processing of the files for recording, and the actual burning of the files to the target optical media. The recording speed of the selected data is effected by such variables as the quantity, size, and location of the selected files, the time required to process the selected data files for burning to a target optical media, and the write speed of the optical media recording device selected for the burn.
In pursuing efforts to increase the speed of recording to optical media, or decreasing the recording time, the quantity, size and location of selected files can be treated as constants, and hardware improvements are regularly improving the recording speed of optical media recording devices. The processing of data files for recording presents additional opportunities for developing faster recording to optical media while maintaining simplicity for ease of consumer use.
The prior art processing of files in preparation for burning to optical media consists generally of a plurality of process operations including such operations as the examination of selected data files, the creation of record data structures, the determination of a writing order, the creation of ordering data structures, the generation of a file system, and other such process operations to enable the locating of selected source files and burning of the files to a target optical media.
One of the plurality of process operations performed in the preparation of selected files to be burned to optical media is the generation of the file system. Typically, the generating of the file system includes the mapping of the source path of each of the files selected to be burned to an optical media, in addition to a plurality of process operations completed to place each of the selected files onto the target optical media. All files to be burned to an optical media are entered into a database. This database calls a source path from a path table or path tree configured to contain a file source path for each of the files selected to be recorded. During a typical recording process, the processing of the files in preparation for the burn includes the verification of each of the selected files to ensure that they exist in the location identified, that they can be opened, that they are the size that they have been identified to be, and other such verification processes. Each file in the constructed database is verified, and as each file is verified, the database calls the path tree or path table to locate a selected file at its source using the stored source path.
FIG. 1A shows a block diagram 10 of this single process of calling the source path. A database 12 is constructed during the processing of the files selected for recording to an optical media in preparation for the burn. The database 12 includes, for example, the source file name, location, size, type, and other such identifying data. The processing operations include, for example, the verification of the selected files in which the general integrity of the files is verified in preparation for burning the files to a target media. As each file is verified, the database 12 calls the path tree 14 to obtain the source path for the selected file.
Prior art processing is typically configured to conserve memory. Often, the conservation of memory resources is at the cost of performance. In the example of the processing of data files in preparation to burn to a target optical media, the conservation is exemplified in the manner in which the path tree 14 stores and retrieves source paths of files. Each time a source file is stored to the path tree 14 , a short-hand or key is used to identify each node of the source path. FIG. 1B shows a block diagram of an exemplary source path 20 with nodes identified by keys 0 – 6 . In FIG. 1B , a source path that is on root c:\ is shown. The root, c:\, is shown in block 22 and is identified as node 0 at 24 . In the exemplary source path 20 , each node is a directory that can be traced back to root c:\ at node 0 , 24 . By way of example, file 2 in block 52 is in the directory source 6 in block 46 . The directory source 6 is identified as node 6 at 48 . As can be seen, source 6 in block 46 , is a sub-directory of source 5 in block 42 , which is a sub-directory of source 4 in block 38 , which is a sub-directory of source 3 in block 34 , and so forth back to the root, c:\ in block 22 . Each of directories source 1 at 26 , source 2 at 30 , source 3 at 34 , source 4 at 38 , source 5 at 42 , and source 6 at 46 , can contain any number of files or additional sub-directories. Each directory is shown in FIG. 1B as being identified as a node. By following arrows 21 , each node can be traced back to its parent, and eventually to the root, c:\at 22 . An exemplary path for file 2 in block 52 is therefore file 2 in block 52 at node 6 , 48 , which is traced to node 5 at 44 , which is traced to node 4 at 40 , which is traced to node 3 at 36 , which is traced to node 2 at 32 , which is traced to node 1 at 28 and back to the root at node 0 , 24 . A typical path statement for file 2 at block 52 would be: c:\source 1 \source 2 \source 3 \source 4 \source 5 \source 6 \file 2 . A short-hand path notation for the same file might instead be: 6 \file 2 , where it is known that “6” represents node 6 at 48 , and the key for identifying node 6 , 48 , is known or identified in the path tree 14 (see FIG. 1A ).
When files are processed during preparation for burning to optical media, the use of nodes in source paths conserves memory by utilizing a short-hand notation instead of the complete source path. FIG. 1C shows a typical source path 52 a for file 2 at 52 as described above in reference to FIG. 1B . The illustrated source path 52 a identifies file 2 at 52 as a file in the directory at node 6 , 48 . In order to verify file 2 at 52 , however, the entire source path must be identified in order to verify a correct source path for the file, and to locate and verify the file as described above. The source path 52 a therefore calls “get(6)” to return the source path to the last node before the file, and then adds the file, file 2 at 52 , to the node. The prior art convention of storing the source paths using short-hand notation traces the file from the first identified node to the root. In the instant example, the returned path might look like: 6→5→4→3→2→1→0, where the returned source path traces through each node back to the root. Because the path tree has stored the key for each of the identified nodes, the complete source path is provided. Further, because each path for each of the files in the database 12 ( FIG. 1A ) is stored in short-hand notation as illustrated, memory is conserved.
As stated above, the conservation of memory is often at the expense of performance. In the instant example, although memory is saved in the use of the illustrated short-hand notation, each time a file is processed, the path is traced back through each identified node to the root. If a file is close to the root, the processing speed is only minimally impacted as the tracing is through minimal nodes. In the case of files that are located deep within a directory's hierarchy, however, the processing is more complex as files are traced through more and more nodes. When the number of files being processed is great, performance degradation is compounded. A typical recording operation to optical media can include hundreds, even thousands, of files, and processing performance in the manner as just described can be significantly impacted.
In view of the foregoing, what is needed is a method for processing files in preparation for burning to optical media that quickly and accurately identifies the selected file source paths without significantly degrading system performance. The method should be able to be implemented in existing applications, and should be configured to provide a consumer with fast and efficient file processing of selected files for burning to optical media without requiring specialized knowledge or skill on the part of the consumer.
SUMMARY OF THE INVENTION
Broadly speaking, the present invention fills these needs by providing a method for processing data to be recorded to optical media. The present invention can be implemented in numerous ways, including as a process, an apparatus, a system, a device, a method, or a computer readable media. Several embodiments of the present invention are described below.
In one embodiment, a method for processing data to be recorded to optical media is disclosed. The method includes receiving a request to record data to optical media, and then mapping a source path for the data. The source path is saved to a database. The source path includes a complete path from a root directory to a file location of the data, and the source path is retrieved to record the data to optical media. The source path is retrieved in a single step.
In another embodiment, a computer implemented method for processing data to be written to an optical media is disclosed. The computer implemented method includes identifying files selected for writing to the optical media, and then for each identified file, determining whether the identified file has been previously written to the optical media. If the identified file has been previously written, the computer implemented method copies the file path for the previously written file to a file database. If the identified file has not been previously written to the optical media, the computer implemented method determines whether a parent directory of the identified file has been previously mapped to a source path of the parent directory. The mapping of the parent directory is used to generate a file source path for the identified file if the parent directory has been previously mapped. Otherwise, the source path for the identified file is traced to the source. Any previously mapped parent directory between the identified file and the source is used, if available, to generate the file source path for the identified file. The file source path is saved to the file database, and the identified files are written to the optical media using the file database.
In still a further embodiment, a computer readable media having program instructions for recording data to optical media is disclosed. The computer readable media includes program instructions for identifying a list of files to be recorded and then mapping a source path for each file in the list of files. The source path for each file begins with a root drive and traces a file path from the root drive to the file including any intermediate directories. The source path is saved to a file system database, and further program instructions are disclosed which retrieve the source path for each file in the list of files in order to record the data to optical media.
The advantages of the present invention are numerous. One notable benefit and advantage of the invention is that recording speed and efficiency are greatly improved making the recording of data files to optical media a faster and more efficient task for the average consumer. By saving a complete file source path from root to selected file for each file selected for recording to optical media, fewer system resources are required to process and record data to optical media. The complete file source path is retrieved in a single step, thereby eliminating the resource intensive tracing of each source path node when processing and recording each file. In accordance with the present invention, the complete file source path is returned in a single step when the path is called for each selected file.
Other advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements.
FIG. 1A shows a block diagram of the single process of calling the source path according to the prior art.
FIG. 1B shows a block diagram of an exemplary source path with nodes identified by keys 0 – 6 according to the prior art.
FIG. 1C shows a typical source path for file 2 as described in reference to FIG. 1B according to the prior art.
FIG. 2 illustrates a block diagram of the primary operations in preparing data files to be written to an optical media in accordance with one embodiment of the present invention.
FIG. 3 shows a block diagram of an exemplary directory tree in accordance with one embodiment of the invention.
FIG. 4 shows a flow chart diagram illustrating the method operations performed for rapid processing of files to burn to an optical media in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An invention for processing data in preparation for recording to optical media is disclosed. In preferred embodiments, a computer implemented method is provided which includes saving file source paths as complete path statements from the root drive or directory to the selected file or files for recording to optical media. The complete source path is then retrieved in a single step for processing and recording without repeated and successive tracing back through intermediate parent directories to the root drive or directory. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be understood, however, to one skilled in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known process operations have not been described in detail in order not to unnecessarily obscure the present invention.
FIG. 2 illustrates a block diagram 100 of the primary operations in preparing data files to be written to an optical media in accordance with one embodiment of the present invention. The method is applicable to writing data files to any type of optical media (e.g., CD-R discs, CD-RW discs, mini-discs, DVD discs, etc.), and is illustrated by way of example using a common compact disc (CD). The selection of data files to be recorded to CD initiates a burn request 102 . The selection of files can be accomplished in any number of ways including, for example, operator input into the system through the graphical user interface (e.g., dragging a set of files to a CD device icon on a computer monitor), or executing a CD read/write software application and in response to a scripted set of queries, the operator selecting a group of one or more data files to be written to a CD optical disc. The burn request 102 is the selection and identification of a group of one or more data files to be copied from their source and written to a CD optical disc.
Once the burn request 102 has been initiated, a file system database block 104 is generated. The file system database block performs a number of file processing operations to map out source locations of each of the files, to sequence the selected files in a recording order, to determine which files will be sent to system cache during the recording operation, to generate pointers and data structures which are passed to the CD recording engine 106 , and other file processing operations in preparation for the writing or burning of the selected data files to a target optical media 110 . The CD recording engine 106 then reads the selected files in the writing order into the optical CD recording circuitry 108 . The optical CD recording circuitry 108 performs the actual writing or burning of the data files to the optical media 110 .
In the file system database block 104 , the data files are examined and processed in order to prepare for the selected data files to be recorded on to the CD. Several discrete operations occur in the processing of the data files as will be discussed in greater detail below. The file system database block 104 encompasses those various operations that are performed to prepare selected data to be burned to a CD. In one embodiment, the file system database block 104 is a collection of sub-routines or other computer code that functions to manipulate the selected data files, performing functions as described below in the execution of the software application code that records data to an optical media.
In one embodiment, the processing includes examining each of the data files selected for recording to CD and verifying the source location of the file, the file size, the integrity of the file, and other file attributes to enable the writing of the source data file to a destination CD. In order to verify the source file, and in order to enable the CD recording engine 106 to locate and read the file, the file system database block 104 generates a source path for each selected data file. As described in reference to FIG. 1A , a file system database 12 is generated containing a source path for each of the files selected for recording. In one embodiment, the source path contained in the file system database 12 is recorded using abbreviated or short-hand notation. A path tree 14 is created to contain a key associated with each of the file path abbreviations used in the database 12 .
FIG. 3 shows a block diagram 150 of an exemplary directory tree in accordance with one embodiment of the invention. In the block diagram 150 , nodes 1 – 6 are identified, and exemplary source paths are easily traced. The root drive or directory, c:\, is shown in block 152 . The drive designator, c:\, is exemplary only, and as is known, the root can be any of identified drives, also called root directories, integral or connected to a computer system. Node 0 at 151 , is root c:\. The simple directory tree shown in block diagram 150 includes six directories in a single branch, and five files in the sixth directory, source 6 at 164 . As described in reference to FIG. 1B , each directory defines a node of the directory tree. In one embodiment of the present invention, each directory defines a terminal point of a node of the directory tree In FIG. 3 , source 1 at 154 defines the terminal point of node 1 at 176 , source 2 at 156 defines the terminal point of node 2 at 178 , source 3 at 158 defines the terminal point of node 3 at 180 , source 4 at 160 defines the terminal point of node 4 at 182 , source 5 at 162 defines the terminal point of node 5 at 184 , and source 6 at 164 defines the terminal point of node 6 at 186 . Each of nodes 1 – 6 begins at root c:\, 152 . In this manner, a call to retrieve any node is independent of any other node in the directory tree. Unlike the prior art which traced a directory tree through each node from a source file back to the root for the source file, one embodiment of the present invention defines each node from the root, and therefore returns a complete file path from the root to the terminal directory for each node called.
In FIG. 3 , file 2 at 168 is used to illustrate one embodiment of the present invention. As can be seen in FIG. 3 , file 2 at 168 is a file in directory source 6 at 164 . Source 6 at 164 is the terminal directory of node 6 at 186 . If file 2 at 168 were to be selected for burning to optical media, a database entry might list the source path for file 2 at 168 as, <path>=get( )\file 2 . In the path tree, node 6 , 186 , is defined as the entire path from the root to the terminal directory, or in the instant example, c:\source 1 \source 2 \source 3 \source 4 \source 5 \source 6 . File 2 at 168 is simply added on to the source path as a file in directory source 6 at 164 , the terminal directory of node 6 at 186 .
Each of the illustrated directories, source 1 at 154 through source 6 at 164 , can contain one or more files, as well as one or more sub-directories. Additionally, each sub-directory can contain one or more files in addition to one or more sub-directories. As is known, file structures can range from the very simple to the extremely complex. In one embodiment of the present invention, when a file that has been selected to be recorded to optical media is being processed, the parent of the selected file is identified. If a node has been defined with the identified parent as the terminal directory, the selected file is simply added to the previously defined node that terminates with the identified parent directory. If a node that terminates with the identified parent has not been previously defined in the recording operation, a new node is identified that starts with the root and terminates with the identified parent directory. The entire file path is included in the node key which is stored in the path tree. When file processing operations call the source path for the selected file, the source path from root to parent is called in a single step, with the selected file contained in the parent directory that terminates the node.
From the above example, it should be appreciated that simple file and directory structures, and source files that are relatively close to the root, will realize a smaller increment of gain in processing speed over prior art than complex file and directory structures, and in particular, those files found deep within a directory hierarchy. In one embodiment of the invention, the file database 12 (See FIG. 1A ) appears comparable to the file database of prior art with selected files identified by path statements calling a node identifier or short-hand notation, to get the parent of the selected file, and then the selected file added to the node indicating the selected file is contained in the parent directory terminating the called node. The path tree 14 (See FIG. 1A ) can be a larger structure than in prior art since nodes are identified by the complete file path from root to terminal directory. A call for a node, or source path, returns the file path in one step rather than tracing through each intermediate parent directory from the parent of the selected file back to the root. In one embodiment, the additional memory required for the larger structure is minimal, but the increase in processing speed can be significant.
FIG. 4 shows a flow chart diagram 200 illustrating the method operations performed for rapid processing of files to burn to an optical media in accordance with one embodiment of the present invention. The method begins with operation 202 in which a request is received to write a set of files to an optical media. This operation is also known as a burn request. In one embodiment the burn request is received when files are selected, a target optical media recording device is identified, and a command to copy, move, record, burn, or otherwise write a selected file or files from a source location to a destination optical media is executed.
Once the burn request has been received, the method continues with operation 204 in which a first data file is processed for writing to an optical media. As described above in reference to FIG. 2 , the selected files are processed through a plurality of operations in preparation for recording to an optical media. In some applications, several of the processing operations are grouped or combined for efficiency, and the sequence in which many of the processing operations are performed can vary according to the program or application utilized to accomplish the recording of the selected files to the destination optical media. Typically, each of the selected files are processed through a plurality of operations in preparation for recording to optical media. One of the operations is the identification and mapping of a source path, and the saving of the source path to a file database. In one embodiment of the present invention, the source path mapping is a discrete operation performed one file at a time until all files have been saved to the database.
In operation 204 , a first file is processed for writing to an optical media. In one embodiment, the processing in operation 204 is the receiving of the first file to map and save the source path. Once the file has been received, the method proceeds with decision block 206 in which it is determined if the file has been previously written to the target optical media. In some recording operations, multiple copies of the same file are selected to be recorded. In other operations, the same file may have been modified so that the data contained within the file has changed since an earlier or previous selection and writing to the target optical media. In decision block 206 , it is simply verified whether the same file has been previously written to the destination or target optical media. If so, a “yes” to decision block 206 , the method advances to operation 220 in which the file path is copied into the database. Operation 220 is discussed in greater detail to follow. If the file has not previously been written to the destination optical media, a “no” to decision block 206 , the method advances to operation 208 .
In operation 208 , the parent directory of the selected file is determined. As is known, any directory can contain a plurality of files, and the determination of a source path for any file is the tracing of a file through its parent, and any subsequent parent directories to its root.
The method next continues with decision block 210 in which it is determined whether or not the parent directory has been previously mapped to the destination or target optical media. If so, a “yes” to decision block 210 , the method proceeds with operation 212 in which the file path for the parent directory is copied. The method next adds the data file to the file path in operation 214 . In one embodiment, the file path for the parent directory that is copied in operation 212 is an abbreviation or short-hand notation for a node identifier. As illustrated in FIG. 3 , a short-hand identifier for a node notation might be a numeric identifier. In another embodiment, the identifier might be an alpha-numeric notation, and in yet another embodiment, the identifier is noted in machine code. If the source path of the parent directory has been previously identified and saved as a node, the parent directory of the file being processed terminates the node. When the file is added to the abbreviated or short-hand node notation corresponding to the file path of the parent directory in operation 214 , the resulting file source path indicates the selected file being processed is located in the parent directory that terminates the previously identified node.
Following the adding of the data file to the copied file path in operation 214 , the method continues with operation 220 in which the complete file path is saved to the file database. In one embodiment, the saving of the complete file path is in short-hand or abbreviated notation as described above. It should be noted that the previously mapped file path terminating with the parent directory that is identified with an abbreviated or short-hand notation node identifier is saved in the path tree. In one embodiment, the complete path beginning with the root and terminating with the parent directory is saved under a key in the path tree corresponding to the node identifier. Therefore, a path in the file database described with a node identifier and the selected file, is returned with a complete source path from the path tree.
If the parent directory of the selected file, the file currently being processed, has not been previously mapped to the target or destination optical media, a “no” to decision block 210 , the method advances to operation 216 . In operation 216 , the source path to the root, or to the first previously identified and mapped node, whichever comes first, is traced. In one embodiment of the present invention, a node starts with the root, and terminates with the parent directory of the selected file being processed. If the tracing of the file path arrives first at a previously identified node, the remaining path to the root is saved under the key corresponding node identifier in the path tree and is called to complete the path. If the tracing continues without reaching a previously identified node all the way to the root, no previously defined node is called, and in either case, the traced source path from the root and terminating with the parent directory defines a new node. In another embodiment, if it is determined the parent directory has not been previously identified and mapped, the source is traced all the way to the root whether or not previously identified nodes are encountered.
In one embodiment, the tracing of the source path in operation 216 includes the identification of the source path from the root drive or directory and terminating in the parent directory as a node. The complete source path is assigned a node identifier for short-hand or abbreviated notation, and saved under the corresponding key in the path tree. Once the path has been traced, and the complete source path saved in the path tree, the method continues with operation 218 in which the selected data file, the file currently being processed, is added to the file path. The method then continues with operation 220 in which the file path is copied into the database. In one embodiment, the copied file path includes the short-hand or abbreviated node identifier and the selected file.
Following operation 220 in which the file path is copied into the database, and previous operations in which complete source paths have been saved to the path tree, the method advances to decision block 222 where it is determined if there are more files to process. In the instant example, the method has been illustrated with a first data file for recording to optical media. If there are more files selected for recording to the target or destination optical media, a “yes” to decision block 222 , the method advances through operation 224 in which the next data file is processed for writing to optical media, and loops back to decision block 206 where it is determined if the next data file has been previously written to the target or destination optical media. The method is then repeated as described above for the first data file. In operation 224 , as described for operation 204 , the processing of the next data file includes receiving a next data file for mapping and saving a source path. The method repeats as described for each of the data files selected to be written to a target or destination optical media. Once all of the files have been processed, a “no” to decision block 222 , the method is done.
In accordance with one embodiment of the present invention, following the processing of each of the files selected for burning to a target or destination optical media, a file source path for each of the selected files is saved for each file in a file database. The file database includes a source path in an abbreviated or short-hand notation. A file path tree contains a key associated with the abbreviated or short-hand notation which returns the complete source path from a root drive or directory to the selected file. In this manner, the retrieval of the source path of a selected file during the burning of the selected file to a destination or target optical media, is a one-step operation without additional processing time and resources dedicated to tracing a file through each source path node to a root.
The invention may employ various computer-implemented operations involving data stored in computer systems. These operations are those requiring physical manipulation of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. Further, the manipulations performed are often referred to in terms, such as producing, identifying, determining, or comparing.
Any of the operations described herein that form part of the invention are useful machine operations. The invention also relates to a device or an apparatus for performing these operations. The apparatus may be specially constructed for the required purposes, or it may be a general purpose computer selectively activated or configured by a computer program stored in the computer. In particular, various general purpose machines may be used with computer programs written in accordance with the teachings herein, or it may be more convenient to construct a more specialized apparatus to perform the required operations.
The invention can also be embodied as computer readable code on a computer readable medium. The computer readable medium is any data storage device that can store data, which can thereafter be read by a computer system. Examples of the computer readable medium include read-only memory, random-access memory, CD-ROMs, CD-Rs, CD-RWs, magnetic tapes, and other optical data storage devices. The computer readable medium can also be distributed over network coupled computer systems so that the computer readable code is stored and executed in a distributed fashion.
Although the foregoing invention has been described in some detail for purposes of clarity of understanding, it will be apparent that certain changes and modifications may be practiced within the scope of the appended claims. Accordingly, the present embodiments are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope and equivalents of the appended claims. | Methods for processing data to be recorded to optical media are provided. In one example, a method includes receiving a request to record data to optical media. The method then maps a source path for the data from a root directory through any intervening parent directories to the file location of the data, and saves the source path in a database. When saving the source path to the database, node identifiers are used to represent individual nodes of the source path with corresponding keys to the node identifiers saved in a path table. The method further provides for the complete source path for each file of the data to be recorded to be retrieved in one step when processing and recording the data. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Current U.S. Class: 607/48 Intern'l Class: A61N 001/36 Field of Search: 128/898, 600/598, 604/154, 606/185, 189, 607/2, 3, 46, 48, 50, 62, 63, 69, 115 U.S. patent Documents: U.S. Pat. No. 4,180,079 December, 1979 Wing 607/69 U.S. Pat. No. 4,276,879 July, 1981 Yiournas 604/154 U.S. Pat. No. 4,699,143 October, 1987 Dufresne et al. 607/46 U.S. Pat. No. 4,759,368 July, 1988 Spanton et al. 607/46 U.S. Pat. No. 4,832,032 May, 1989 Schneider 607/115 U.S. Pat. No. 4,989,605 February, 1991 Rossen. 607/46 U.S. Pat. No. 5,041,974 August, 1991 Walker et al. 607/63 U.S. Pat. No. 5,183,041 February, 1993 Toriu et al. 607/46 U.S. Pat. No. 5,211,175 May, 1993 Gleason et al. 600/548 U.S. Pat. No. 5,304,207 April, 1994 Stromer 607/3 U.S. Pat. No. 5,350,414 September, 1994 Kolen 607/62 U.S. Pat. No. 5,354,320 October, 1994 Schaldach et al. 607/46 U.S. Pat. No. 5,374,283 December, 1994 Flick. 607/46 U.S. Pat. No. 5,387,231 February, 1995 Sporer 607/48 U.S. Pat. No. 5,395,398 March, 1995 Rogozinski 607/50 U.S. Pat. No. 5,397,338 March, 1995 Grey et al. 607/115 U.S. Pat. No. 5,476,481 December, 1995 Schondorf. 607/2 U.S. Pat. No. 5,735,868 April, 1998 Lee 606/189 U.S. Pat. No. 5,968,063 Oct., 19, 1999 Chu, et al. 606/185 U.S. Pat. No. 6,058,938 May, 2000 Chu, et al. 128/898
BACKGROUND OF INVENTION
[0002] Muscle injuries described in this work are muscle-strain injuries (MSI) and repetitive strain injuries (RSI). MSI and RSI are frequently associated with work-related muscular-skeletal disorders (WMSD). Strain injuries include those to the bone, ligament, tendon, joint-cartilage, synovial tissue, muscle, vascular system, and nervous tissue. Strain injuries are often related to a certain type of work activity, poor posture, biomechanics, or lifestyle activity.
[0003] Strain injury (SI) is a common name for conditions such as cumulative trauma disorders, repetitive strain injuries, typing injuries, and related conditions like carpal tunnel syndrome, trigger-finger, tennis-elbow, whiplash, etc.
[0004] Strain injuries can be divided into two classes:
[0005] 1) Acute injury due to excessive force being applied to the muscle when lifting or falling.
[0006] 2) Chronic injuries due to excessive repetition, as in typing.
[0007] MSI describes injuries to the soft tissues, which occur due to excessive force being applied to the muscle(s). RSI, or cumulative trauma disorder, describes injuries to the soft tissues that are caused, over time, by repetitive actions.
[0008] Muscle strain injuries (MSI) are related to acute muscle strain injuries, such as whiplash, and repetitive strain injuries (RSI) are related to chronic-type injuries. RSI is a result of the muscles being in a high-alert mode during repetitive movements, which stress these in-use muscles. Small repetitive movements can injure muscles as well as tendons. Programmers, computer users, hairstylists, dentists, cooks, etc. often acquire wrist or shoulder problems due to prolonged repetitive motion of the same muscles. A person may suffer for several months, or even years, often bringing down their quality of life.
[0009] MSI are associated with isotonic contraction, where there is actual physical damage to muscle cells. With RSI, there is isometric contraction and impairment of the blood flow. There is an imbalance between the blood demand and supply. An enhanced blood flow would create a positive impact in both conditions.
[0010] Strain Injuries pain-sensitivity based classification:
[0011] â□Muscle injury, up to 10% of muscle diameter, is unnoticed, no pain.
[0012] â□Muscle injury, up 10-30% of muscle diameter, is painful during palpation.
[0013] â□Muscle injury, up more than 30% across the muscle distance, will make the patient complain about muscle pain and movement limitations.
[0014] The depth of the injury is more important than the length because of the impact on muscle performance. In addition, that is why the distal end of muscle is more vulnerable. The across-distance of the vastus medialis, for example, is much greater than at the insertion of the muscle (patella).
[0015] There is a tendency to frame a patient's complaints into syndromes, which allow for collecting statistics by tracking the incidence among occupations. Unfortunately, we know more about statistics than we do about the nature of strain injuries.
[0016] “In 1996/97, nearly two million Canadians, aged 12 and older, sustained repetitive strain injuries (RSI) that were serious enough to reduce their usual activities. These injuries, caused by overuse of certain muscles, included carpal tunnel syndrome, tennis-elbow, tendonitis, and back injury. Injuries to the back or spine accounted for the greatest share (20%) of RSI among men. Injuries of the wrist, hand, or fingers were the most common among women (25%).”(National Population Health Survey: Cycle 2, 1996/97).
[0017] The management of chronic pain due to repetitive strain injuries was a $95 billion dollar business in the United States in 2000 according to the U.S. Occupational Safety and Health Administration (OSHA) estimations. These numbers indicate that strain injuries are widespread and costly, and can last for years, and surgery is often necessary.
[0018] There are a few non-surgical approaches to the MSI/RSI/WMSD problems, but every approach has limitations that reduce its efficiency.
[0019] Drugs: Painkillers, anti-inflammatory medication, and muscle relaxants
[0020] Â Painkillers help to control the pain level and slow the inflammation; the recurrence of pain is high after returning the patient to the same work or lifestyle. In addition, because of instant pain relief, the proper treatment will be postponed, sometimes leading to overuse of these drugs. Painkillers should only be used for emergency help. Anti-inflammatory medication: hormone injections, sometimes called, “despair therapy,” suppresses inflammation activity and body immune responses, and reduces capillary permeability. The mechanism of hormone actions is not yet fully understood.
[0021] Â Muscle relaxants block inter-neuronal activity in the descending reticular formation and spinal cord. Muscle relaxants increase muscle-pain-threshold and reduce muscle response to rehabilitation therapy (electrical stimulation, exercises). Some muscle relaxants cause withdrawal effects.
[0022] Another side effect of drugs is a pain reduction as well. It sounds like a paradox but, if the patient will take a medication and do not take a rest. He/she will cause more the harm than a without a medication.
[0023] Massage improves blood and lymph circulation, and increases metabolism in the superficial muscles. However, the masseur's fingers cannot access deep muscles. Massage of overweight patients is problematic even for superficial muscles. In addition, massage of the injured muscle can be very painful, and is not recommended during the early stage of injury (the first 10-14 days), because of the possibility of worsening the injury.
[0024] TENS electrical stimulation is commonly used for MSI treatment.
[0025] The principle is patch's placements in boundaries of a myotome. Two and more conductive patches apply in one session at once with high frequency for pain relief purpose. The effectiveness of the treatment is short term and reduced significantly by the layer of fat under the skin. Both skin and adipose tissues are rather insulators than conductors; therefore, a weakened electrical impulse can only reach superficial muscles. Latest research (Journal of Physical Therapy) tells us that there is no significant difference between TENS and exercise. We believe that because the main goal of TENS is analgesia.
[0026] Acupuncture-like TENS (AL-TENS) is an electro-acupuncture combining TENS″ principles, like needle insertion in boundaries of one myotome, and low frequency current. The purpose is the same as TENS, to produce analgesia.
[0027] In the last few years, more research has been done on efficacy of TENS and AL-TENS. The conclusion is that over a period of three to six months TENS and AL-TENS are not effective for low back pain.
[0028] Exercise programs are not recommended during an acute stage of MSI, but are definitely needed during the rehabilitation stage. Exercise improves the overall blood and lymph circulation. Stretching is the most popular exercise for MSI, but improper or very extensive exercise can create additional injury and pain. Exercise only, can not cure MSI.
[0029] Chiropractors use spine alignment to treat low back pain and sore neck The approach is right; in some cases pain is created by one or a few nerves pinched by the out-of-alignment vertebrae. Proper spine alignment is provided when muscles are symmetrically attached to the vertebra. If a muscle from one side is swollen and shortened, it will pull the vertebra to the side. It is clear that the proper spine alignment cannot be achieved without treating the shortened muscle. Chiropractic patients benefit more from combined muscle treatment as well as spine alignment.
[0030] Acupuncture has a few very important advantages:
[0031] a) Direct treatment
[0032] b) May reach a muscle, no matter how deep
[0033] c) Uses no medication
[0034] d) No side effects
[0035] Disadvantage of acupuncture: Since all acupuncture schools teach diagnostic tools, not every practitioner is able to practice without a “recipe book.” It decreases the value of acupuncture and sometimes discredits it.
[0036] Besides the above-mentioned MSI treatments, other methods that use acupuncture principals and needles should be noticed.
[0037] Â Dr. Gunn's intra-muscular stimulation (IMS) is a treatment for muscle spasm, or shortened muscle, by desensitizing the muscle trigger-point. The treatment is based on a neurological approach to the problem. Dr. Gunn states that the injured nerve is hypersensitive (Cannon and Rosenblueth' Law of Denervation) and can be desensitized by needle insertion and manipulation. A needle is inserted into the spasm area and followed by needle grasp and muscle's fasciculation. Visually, it appears as a muscle twitch. The treatment requires a needle manipulation on each shortened muscle. It is difficult to employ the technique on shortened deep muscles near the vertebra, under blind control. The treatment is quite painful.
[0038] Â Dr. Chu (U.S. Pat. No. 6,058,938, et al. May 9, 2000) found that the acu-needle inserted only once into the muscle does not provide the necessary stimulation. She offers twitch-obtaining intramuscular electrical stimulation, which is performed by motor end-plate employment. The rate of stimulation is 10-50 Hz. Both electrodes (Teflon-coated needles) are placed, subcutaneous, about 15-25 mm away from each other. It elicits “twitches in a small portion of muscle, visible as fine jerking of the stimulating needle or as fasciculation-like twitches.” This is very effective and cost-efficient technique, but produces only local intra-muscle stimulation. To treat the whole muscle, the needle insertion has to be repeated in at least four treatment points within the afflicted muscle. Note: the repetitive needling can create stress for some patients.
SUMMARY OF INVENTION
[0039] In view of the foregoing, the principal object of the present invention is to provide a simplified and standardized treatment that medical personnel, including but not limited to doctors, can rapidly be trained on, thus making the treatment available at low cost and on a mass scale. This will lead to reduced absenteeism from work, payoff for worker's compensation, and disability expenses. In addition, a larger number of pain afflicted persons may enjoy happier and more productive and fulfilling lives.
[0040] The further object of the invention is to improve the effectiveness of recent myotherapy techniques, i.e., to increase and prolong the resultant pain relief, and reduce tissue trauma and patient discomfort associated with the IMS procedure.
[0041] These and other objects are achieved in accordance with the present invention by a method of conducting an electrical intramuscular stimulation through lower motor neuron therapy session.
[0042] There are three variations of the modality:
[0043] 1) osteotome treatment
[0044] 2) myotome treatment
[0045] 3) neurotome treatment
[0046] The commonalties between these three variations are:
[0047] a) Electrode's location that used for stimulating of a treatment area: one needle always placed on a vertebra (periosteum) and second needle or electro-conductive patch in distal area of nerve distribution.
[0048] b) Electrodes' polarity: (−) for vertebra and (+) for second electrode.
[0049] c) The electrical impulse frequency: 1 to 2-2.5 Hz serves the purpose of microcirculation rehabilitation.
[0050] d} The voltage lays in more broad numbers than frequency - - - 5 mAmp (some neck muscles) to 55 mAmps. The voltage number depends on precise needling the periosteum, the distance between two electrodes and nerve diameter between two electrodes.
[0051] 1) Osteotome 3electrical Stimulation
[0052] Treatment is applied to a vertebra which is a sensitive to finger pressure. Intrinsic muscles, tendons, and other soft tissues that are in direct contact with the vertebra compose an osteotome. Osteotome structures can be a source of pain and have to be treated. The (−) electrode (needle) is placed on the vertebra and second (+) electrode (patch in this case),on a stomach. It is very important that the tip contacts periosteum. The greater electrical charge concentrates on a tip of a needle and therefore provides stimulation to tissues surrounding vertebra. The patch supports the current direction from (−) to (+) and it must be placed within the boundaries of area of nerve distribution of the vertebra. The treatment provides easy and effective stimulation for unattainable structures around vertebra: tendons, nerves, muscles, bones, and vessels.
[0053] [0053]FIG. 1: Osteotome Electrical Stimulation.
[0054] 2) Myotome Electrical Stimulation:
[0055] Myotome treatment aims to release a pressure on the inside injured muscle nerve created by inter-muscular oedema (intramuscular nerve compression)At first, recognition of sore muscle is based on the movement restriction or pain provoking movement. Secondly, the vertebra responsible for nerve distribution in the injured muscle has to be recognized as well. An acupuncture needle is inserted into the muscle's tissue in such manner that the tip of the needle is placed approximately in the middle of the muscle. The second acupuncture needle places on a vertebra contacting periosteum. The vertebra and the muscle should be in the boundaries of the same myotome. The main idea is based on a concept that electrical current always goes by the best conductivity way. Therefore the closer needle's tips is placed to a nerve the lesser voltage is required.
[0056] [0056]FIG. 2: Myotome electrical stimulation
[0057] Explanation. The distance between needles must be grate to obtain the more chances for impulse to go through the nerve. The mayor challenge is vertebra needle; it must be placed on right spot (periosteum) which is almost in intimate contact with a spinal nerve. Therefore the current will go through nerve pathway directly to the tip of second needle which is placed into muscle nerve net and stimulate the whole muscle. The current flows from the tip of vertebra needle to periosteum to spinal nerve to a muscle and to a second needle. The muscle needle is withdrawn from the muscle upon 7-10 min of the stimulation. The foregoing steps are repeated to elicit contraction at as many muscles as required upon a limit of time, boundaries of myotome and common sense.
[0058] 3) Neurotome Electrical Stimulation
[0059] A pain patient suffer may come from a major nerve compressed between muscles (sciatic) or because of narrowing the space where it goes trough (median nerve trough carpal tunnel). Compressed nerve causes a lot of pain and discomfort at both scenarios. Removal of the compression is a main goal of the treatment. The electrodes have to be place on a beginning of the nerve and the distal area of the nerve to make sure the impulse will go trough the nerve. One needle (−) electrode is placed on a periosteum of vertebra responsible for the nerve distribution and (+) electrode, (electro-conductive patch) attaches on a skin on a distal part of the nerve, like calf, foot or hand, preferably on a spot of short distance between nerve branch and skin. The electrode placement will provide stimulation to nerve and other structures contacting the nerve. An impulse with the frequency will reduce the muscle and nerve swelling; restore microcirculation and create the necessary room for nerve pathway. The essential element of the procedure is to recognize involved vertebra and the level of compression. The patch must be placed far below the compression level.
[0060] [0060]FIG. 3: Neurotome Electrical Stimulation
[0061] The above and other objects, features, and advantages of the present invention will be readily apparent and fully understood from the following detailed description of preferred embodiments, taken in connection with the appended drawings
BRIEF DESCRIPTION OF DRAWINGS
[0062] [0062]FIG. 1: Osteotome Electrical Stimulation. The needle is placed in touch with impaired vertebra's periosteum. The patch is placed on a median line of the abdominal wall within boundaries of the spinal nerve distribution, basically on a vertebra's cross sectional line and frontal median line. Wires are attached: (−) to a vertebra's needle and (+) to a patch on a stomach wall.
[0063] [0063]FIG. 2: Myotome Electrical Stimulation. The figure is a highly simplified schematic view of an electrical field distribution when needle #1 is placed on a vertebra's periosteum and needle #2 in boundaries of nerve distribution of the vertebra. The current flows through the periosteum to the spinal nerve to the nerve and to the muscle. Negative polarity is provided to #1 needle and positive polarity to #2 needle by any TENS or electro acupuncture device as soon the device can provide a single monophasic/biphasic impulse with a frequency 1-2,5 Hz and intensity in a range of 5-50 mAmps. Patients must feel no irritations but powerful contractions because of efficient conductive way of electrical impulse distribution between two needles. The first needle is placed in touch with impaired vertebra's periosteum. The second needle is placed into the muscle, the source of pain
[0064] [0064]FIG. 3: Neurotome Electrical Stimulation. The needle is placed in touch with impaired vertebra's periosteum. The patch is placed in a distal area of involved nerve branch. It supposed to be the area where the distal part of the nerve comes close to skin. Example: In a sciatica case, it is the area of distal lateral side of gastrocnemius muscle. In a carpal tunnel syndrome case, it is a base of the wrist on a palmar side
DETAILED DESCRIPTION
[0065] General Principles
[0066] 1.A sound knowledge of anatomy is essential. The trainee is referred to the textbook Gray's Anatomy of the Human Body (any edition) and to the physician/inventor's textbook Nikolay Yelizarov: Treatment for Muscle Strain Injuries. ISBN 1-932303-07-03.
[0067] The treatment program got a chose abbreviation as MONES (myotome, osteotome, neurotome electrical stimulation).
[0068] Myotome Electrical Stimulation (MES).The main goal of any treatment is to bring the healing factor, as directly as possible, to the injured organ. The most beneficial treatment comes from the precise delivery of the treatment. This rule is applied to any field of medicine. Therefore, it applies to muscle-strain injury. The best tools to provide this healing are the acupuncture needle and inducing muscle contraction in a solitary metamere. (A needle can reach almost any skeletal muscle). The treatment, within metamere boundaries, will rehabilitate all noticed and unnoticed injuries.
[0069] Muscle contraction will restore impaired microcirculation. The power of induced muscle contraction will give feedback for correct placement of the needle. Successful contraction of idle muscles will help the edema and restore microcirculation-the necessary recovery tool that was discussed above.
[0070] The muscle venous-blood circulation is performed by muscle contraction. Often an injured muscle is unable to obtain sufficient contraction to move the blood out due to some ruptured muscle threads; edema is most often the cause of the pain—pinched nerve fibers between swollen muscle threads or muscles. So every contraction (like simple exercise), creates more excessive pressure inside the muscle, and therefore, pain, which limits the movement. A single electrical impulse sent to a single injured muscle through a natural pathway (lower motor neurons) will create a like physiological contraction which will be sufficient enough for good blood circulation inside the muscle.
[0071] The most difficult point for treatment is to employ the lower motor neuron. Two needles should be used to obtain muscle contraction. An electrical impulse follows physics' law and takes the path of least resistance. Two needles inserted inside the same single muscle, or within boundaries of the myotome, will stimulate a part of the muscle by employing only a single part. Usually, especially in long muscles, the injured part is presented through the length of almost the entire muscle. Therefore, it is a complicated process to insert two needles at the same depth in the same muscle, especially if the muscle is covered by another muscle. In addition, there are always a few injured spots inside one muscle, making the procedure more complicated and painful. Also, patients will always tell the practitioner about uncomfortable feeling around the needle(s) because of the electrical irritation. The stimulation has to be general and direct.
[0072] To effectively stimulate the muscle, we have to use a lower motor neuron. This is the best way to produce conductivity within the body's system. Again, the difficult point is the implementation itself. For many reasons, we cannot insert a needle into the nerve pathway, particularly because of the risk of pain and nerve damage. We have to employ the nerve without touching it. Therefore, we need a mediator for it, and a vertebra suits serves this purpose. It is a large structure and is in intimate contact with the nervous system. It is very superficial, is a good conductor of electricity because of the countless contacts between the periosteum and spinal nerves, and it does not have pain receptors.
[0073] Another subtlety is when a needle placed on a vertebra and a second needle, or patch, supposes to employ a specific nerve pathway. It means they have to work in the same metamere. When needles, one on a vertebra and another on the muscle, are established, and stimulation is applied, the impulse goes through the periosteum, nerve root, and nerve branches, then directly to the injured muscle, and stimulates it. If the pathway is well established, the stimulation is effective and painless. The intensity does not have to be great, just efficient enough for the obvious muscle-contraction. The numbers are below: Frequency of the stimulation is important. We know from experience of other practitioners, and many articles about electro-acupuncture, that low frequency stimulates, and high frequency suppresses. For example, Chinese anesthesiologists employ high-frequency electrical stimulation for local anesthesia (suppression of nerve conductivity), with great success. TENS at physiotherapy, uses high frequency, 20-49 Hz for analgesia, AL-TENS uses a set of impulses with low frequency, two-four Hz (burst mode). We believe that only low frequency will support the idea of restoring of blood microcirculation. The relaxation time must be much greater than a time of contraction. Contraction induced by single electrical impulse pushes the blood out the muscle like a wringing and creates pressure gap necessary for bringing arterial blood in the muscle. Most suitable frequency is one-three Hz. Also, it supposes to be a normal mode, single impulse.
[0074] Neurotome Electrical Stimulation (NES).
[0075] Nerve's anatomy. As mentioned above, we call the metamere an anatomical structure, consisting of dermatom (skin), myotome (muscle), neurotome (nerve) and osteotome (bone). Since dermatom and myotome are more familiar, neurotome, and especially osteotome are not. When we talk about osteotome, we mean mostly the vertebra's periosteum, which is richer on nerve endings, and has more links to the nerve network than does bone.
[0076] Neurotome is more complicated than other parts of the metamere. It consists of the central nervous system (spinal cord) and autonomic nervous system. One of the principal functions of the spinal cord is to serve as the center for reflex actions. Spinal nerves are paths of communication between the spinal cord and the rest of the body. Each of the 31 pair of spinal nerves is connected to the spinal cord by two roots. The anterior, or ventral root, conducts impulses, via motor neurons, to muscular-skeletal systems, and anterior or visceral, brings information to the spinal cord via sensory fibers. The dorsal root of each spinal nerve has a spinal ganglion, which is located in the intervertebral foramen. Distal to the spinal ganglion, and just outside the intervertebral foramen, the dorsal and ventral nerve roots unite to form a spinal nerve, which divides almost immediately into ventral ramus (viscera) and dorsal ramus (muscles). The autonomic nerve system is made be both a sympathetic and parasympathetic nervous system. The characteristic of pain is different for the central nervous system and autonomic nervous system.
Table Peculiarity of clinical Visceral pain picture (ANS) Somatic pain Pain sensation Smarting pain Nagging, aching, shooting, pulsing Feeling”s location Diffusely spreads Definite location, certain area Permanency of location Migrates Does not migrates Area of primary Cannot always tell Always clearly appearance determined Area of referred pain Determination is Determination is difficult easy Referred pain to reflex Yes No zone Repercussion Yes No Reflex impairment Visceral reflex Somatic reflex impairment impairment Light irritation Negative May distract the influence pain pain increase Sore spots Around vessels, Osteotome, visceral ganglia myotome, dermatome Forced posture No Yes Sleeping Always disturbed Falling asleep is difficult Pain syndrome pattern Sudden, Usually is paroxysmal permanent Emotional feelings Fear is common No fear Analgesics efficiency Low Helpful for certain period Opiates efficiency Reduces but does Eliminates pain not eliminate the pain Antispasmodics/smooth Temporarily Not effective muscle relaxants effective
[0077] The difference helps us to recognize if the hernia has occurred and enzyme leakage brought the irritation to an advanced stage. The irritation spreads to the autonomic nervous system, and the pain-pattern usually gets changed.
[0078] NES (neurotome electrical stimulation) is a treatment of the involved neurotome, by indirect stimulation via osteotome and dermatome. Indications, that such stimulation is required are when the patient complains of a painful vertebra and distal somatic neuralgic pain, with its original source at the vertebral column. Feelings of pain are often described as burning, pressure, twisting, or even dizziness. Medical investigation, and, perhaps, subsequent disc treatment may be required due to the rupture of the nucleus pulpous.
[0079] The main purpose of this treatment is to send electrical impulses through the dorsal root and lower the motor neuron to the distal part of the nerve (skin endings). The pointed entrance and disperse, exit at the determined area to effectively employ the nerve without touching it. The secondary benefit is a contraction of muscles which helps release nerve compressed by strained muscles. As the stimulation is confirmed, we may observe a contraction of muscles innervated by the nerve branch. The treatment is most beneficial for cases like sciatica or carpal tunnel syndrome, as described below.
[0080] Osteotome Electrical Stimulation (OES).
[0081] OES is designed to stimulate muscles and other soft tissues (as well as the vertebra itself) in close contact with the involved vertebra. The need for such treatment is based on the concept that vertebra-supporting muscles, of any size, play a significant role in the alignment of the spine. Therefore, long-term backache almost always means a displaced and sore vertebra. Finger pressure applied on such a vertebra will produce discomfort and pain. Sets of such treatments will relieve back pain and improve the paravertebral muscle condition. In addition, some patients got their spine alignment back without any vertebra manipulation.
[0082] A negative electrode (needle) is placed on the periosteum of the vertebra. The needle does not need to go inside the bone. In fact, as soon as the needle contacts the periosteum, the stimulation may start. A positive electrode (an electro-conductive patch) is placed on a front area within the boundaries of the dorsal root. The treatment looks like a neurotome stimulation but actually serves another purpose. An absence of a major nerve between two electrodes will create a stronger electrical field in the area of the needle tip, and will transmit it to surrounding muscles and soft tissues. Strong pounding of spinal muscles will confirm a well-installed treatment.
[0083] Treatment for Low Back Pain
[0084] Lower back pain is the most frequent malady, affecting one in three people over the age of 45. Most frequently affected areas are the L4-5 and S1-2 vertebrae.
[0085] During an injury, a part of a muscle is excluded from the performance. Usage of the injured muscle is painful, and limits body movement, which creates a specific posture. The posture usually brings unequal biomechanical pressure on the side of the vertebra. The unequal pressure on a disk, over a long period, creates cracks, or a hernia, which can compress a nerve branch and develop into sciatica. The hernia situation may only be solved by surgery, or disk treatment, with an elimination of the cause of irritation.
[0086] The Clinical Symptoms Characterized by Somato-sensory Feeling.
[0087] The patient with a sharp pain and no somato-sensory feelings does not fit the category, because the nerve branch may be pinched, however at a lower level. It means the nerve is pinched inside, or between muscles. This situation often confuses some practitioners. The Merck Manual, states, “â□the pain most commonly caused by peripheral nerve root compression is from intra-vertebral disk protrusion or intra spinalâ□The nerves can also be compressed outside the vertebral column, in the pelvis or buttocks.”(Section 5) Nobody doubts it, but I repeat, many doctors are convinced that 85-90% of backache originates from soft tissues, and, therefore, may be unnecessarily conservative in their treatment of the patient.
[0088] General overlook: such signs as asymmetry in the hips or thighs, hollow back, overweight, and scoliosis, help us recognize what muscles or side of the body are more vulnerable to muscle strain. Therefore, patients who mention the above pre-existing conditions need more prolonged initial sessions, and a clear understanding of their condition, which requires preventative treatment in the future.
[0089] The next step is an examination of the troubled area: Palpitate and recognize every sore spot in the troubled area. Watch for the direction of the examined muscle; it will help to recognize the muscle. Memorize or mark them. There are always a few of them. Palpitate and recognize sore vertebrae when finger pressure is applied. Mark them. Relate sore spots and sore vertebrae. Choose one or two of the most sensitive vertebrae for the pressure treatment.
[0090] The treatment's goal is usually divided into two parts:
[0091] Part 1) Stimulation of the vertebrae
[0092] Part 2) Stimulation of sore spots (muscles) of the area
[0093] Part 1) Stimulation of the vertebrae, means the stimulation of all deep muscles (semispinalis, multifidus, rotatores) that support the vertebrae. Every strain starts from part of the muscle, and if untreated or aggravated future, will spread over a wider area, ultimately involving other muscles. This condition happens because of the impaired ability of the injured muscle to contract, causing neighboring muscles to take over its function. The more time that patients go without treatment, the more chances of involvement of deep muscles/tendons. The stimulation of palpated sore muscles is usually includes sore spots on the iliocostalis lumborum, longissimus dorsi, spinalis dorsi or quadratus lumborum.
[0094] a) To place a needle on a process spinous
[0095] b) To find a place for a patch.
[0096] The area between the navel and pubic bone will support electrical stimulation with the needle placed on the vertebrae from L4-5 to S1-2. Practice tells us that this area will support electrical stimulation, even wider, using vertebrae L2-3 to S2-3, due to the metamere overlapping.
[0097] A patch is more convenient than a needle on the belly for two reasons. It is less painful, and it supports more powerful stimulation of an active needle on the back.
[0098] After a stimulation of deep tissues surrounding a vertebra, we have to provide treatment for sore muscles, which the practitioner has to find, localize, recognize and provide the stimulation to these muscles.
[0099] An Example of Treatment for an Average Low Back Pain (Osteotome Stimulation).
[0100] A needle is placed on the process spinous of L4 and a patch on CV3 (acu-point which is located on 1 inch above edge of pubic bone. The size of the needle for an average patient is 0.35 (30 mm). Electrical frequency is two Hz, with an intensity of 15-25 milliamps. The time for stimulation is 7-15 min. The red (negative) electrode goes on a vertebra and the black (positive) attaches to a patch.
[0101] Note: the patient will experience slight feelings of discomfort, and powerful contractions of the stomach, if there are large fat deposits on the stomach, scars from previous surgery, or the needle did not reach the periosteum. Try to avoid this as much as possible, and do not place a patch on a scar—for example, when scars and recommended treatment spots are the same. The session will be more profound if the patch is moved above the scar proximally or laterally.
[0102] After the process of locating sore muscles, stimulation may be induced by placing one needle on a vertebra and placing another on the injured muscle. The best scenario is when the same needle is employed for both parts one and two, avoiding unnecessary pain to the patient. The “muscle's needle” has to reach the sore spot. To do this correctly the practitioner must calculate the depth of needle insertion, using his knowledge of anatomy and estimation of the obesity of the patient.
[0103] Preferably, the needle is inserted in the middle of the muscle. The size of the needle for an average patient is 0.30×35 mm. The needle for the vertebrae has to be thicker, to avoid misguiding. In this case, the needle size, 0.30×35 mm is optimal. The polarity is always the same—red on a vertebra and black on the patch or muscle.
[0104] An Example of the Treatment Session.
[0105] Place one needle on L4, with the same precautions, and the other one on the painful area of the longissimus dorsi, iliocostalis lumborum, quadratus lumborum, gluteus medium, or gluteus maximus. The electrical frequency should be two Hz, and the intensity should be 15-25 milliamps. This is considered safe, and the “muscle”needle may be inserted as deep as it is needed. A 0.30×75 mm needle is usually large enough even for obese patients. The time for stimulation is 7-10 minutes.
[0106] Sciatica.
[0107] Sciatica is usually a complication of untreated low back pain. From my observations, patients seem to get pain in the lower back first. If they continue with the same lifestyle, or type of work, and don't do anything to prevent worsening their condition, they will develop sciatica signs, or sciatica, because the nerve is being pinched between swollen muscles. (A herniated disk is a different problem and we do not discuss it now.) The result depends on choosing the correct vertebra for stimulation. Stimulation provided above, or especially below, the injured area will be less effective.
[0108] The Treatment for the Average Sciatica.
[0109] Neurotome stimulation. Localize the most sensitive vertebra and place a needle on it. The needle is supposed to be attached tightly to the bone part or even slightly inserted. An active electrode is attached to the vertebra and a patch on acu-point B57.
[0110] A patch works better than a needle because the affected area involves several large nerves and more than one metamere. Point B-57 is related to the bladder channel that is responsible for the low back pain condition. Classical sciatica is usually noted as shooting pain in the direction of the heel, by the leg posterior midline. The patch location should be different if the pain goes in another direction.
[0111] The intensity of the stimulation depends on the precise needle insertion and obesity level of the patient. The best scenario is when the contraction is very obvious and painless. The needle size, 0.30×30 mm, is good for an average person. Frequency is one-two Hz and intensity is 25-40 milliamps. The time for stimulation is 7-15 minutes.
[0112] Myotome stimulation. Sciatica nerve may be compressed by strained hip's muscles like Gluteus medius, piriformis, maximus, obturator internus and gemelli.
[0113] The needling is more complicated because for access to priformis obturator internus and gemilli the patient has be on healthy side with affected limb knee bent and brought to a stomach as much as possible.
[0114] Shoulder and Neck Pain.
[0115] Most shoulder pain can be treated by applying a needle (passive) on the C7th vertebra, and a needle (active) on a sore muscle. The intensity may be less than for back treatment because of the smaller size of the neck/shoulder muscle and the distance between these electrodes. The practitioner must be aware of the depth of the needle insertion into the muscles. The depth depends on obesity level, anatomical location, and size of the muscle. The needle length, 3-3.5 sm, is for an average person and not for a child or an obese client. The practitioner's common sense is the best guide.
[0116] A needle must be applied only into the muscle tissue. So palpation of the area is mandatory to avoid puncturing major blood vessels, nerves, or lungs. The finger must be placed on the muscle, and the practitioner must be sure that the needle goes into the desirable target. Three rules must be applied for any sessions: 1) The target muscle must be hit.
[0117] 2) The session-must be comfortable. There should only be muscle stimulation and contraction, not pain.
[0118] 3) The practitioner must know how far to insert the needle.
[0119] Special considerations should be taken for treating muscles of the lung apex-area such as the levator scapulae, scalenius, and serratus anterior. A thicker “vertebra”needle such as a 0.35-0.40 mm. and shorter like 3.5 sm is preferable for safety reasons. A thin needle is much more flexible; therefore, it will not always go to the desired point.
[0120] Evaluation of the ROM of the neck is necessary to locate the proper area of treatment, side of the neck, layer of a neck muscles. Injuries of the above mentioned muscles are mostly related to MVA (whiplash injury) and require the treatment of a more experienced practitioner than, for example, one who would only treat low back pain.
[0121] Treatment for Average Neck or Shoulder Pain
[0122] A needle on the C5 vertabra, another needle on the levator scapulae, trapezius, or longissimus capiti.
[0123] The frequency 2 Hz, the voltage 15-25 milliamps, the time is 5-10 minThe best way is to needle another muscle once you finish stimulating the previous one. In this way, the patient will have only two needles in him at the same time. The muscle on the front of the neck, i.e. levator scapulae, requires less intensive stimulation, often two-five milliamps.
[0124] Chest Pain.
[0125] The majority of patients seek consultation from a doctor because they are in pain, which is preventing them from working, or otherwise enjoying their life. Complaints of chest pain are special, because it usually makes the patient concerned about their heart.
[0126] If the patients are in the 40-60 age group, chest pain almost always makes them think about a possible heart attack.
[0127] Not every family physician is able to successfully diagnose chest pain without necessary tools. The usual scenariois for the doctor to order blood tests and an ECG. At this point, the patient is a little less anxious because he/she is under observation. Often, the doctor will reach the conclusion that the case is not medical, “it is just a muscle pain.”In this case, the pain usually originates from an area beside vertebra TH3-6, or most common, TH 4-5, on spinalis or semispinalis. The swollen or inflamed muscle irritates the intercostals nerve, and pain radiates toward the nerve ending—sternum. Precise locating and recognition of the sore spot is an important element of successful treatment.
[0128] Treatment: Vertebrae needle is on C7-Th1, while the muscle needle is on the sore spot of the semispinalis or spinalis muscle. Intensity is 15-20 milliamps, frequency is one Hz, duration is 7-10 minutes.
[0129] Upper Neck.
[0130] The muscle-strain injury in the suboccipital region/triangle plays more significant role in causing headache, insomnia, and dizziness than we think.
[0131] Another area requiring a more skilled practitioner is the upper neck. From my experience, I've learned that muscle injury of the suboccipital triangle, made by obliqus capitis inferior, obliquus capitis superior, and rectus capitis posterior major, are often related to headaches, dizziness, insomnia, forgetfulness, and a “not-well-being” feeling. The severity of these complaints relates to the type and age of the injury. The greater occipital nerve and vertebral artery may have influenced the shortened muscles, or put pressure on the swollen musclesThe most frequently damaged muscle is obliquus capitis inferior.
[0132] The treatment: a needle is placed on C2. The needle has to be short and thick to insure it goes into the process spinous. Needling of the muscle, obliquus capitis inferior, requires precise skills, knowledge of anatomy, and the insertion must be done under the left thumb (if you right handed) control. The practitioner locates the muscle and needles it at once without moving the thumb. One hand does the locating, and the other inserts the needle. This process is the best way to control the action.
[0133] The procedure frequency and intensity are same. A few muscles like are levator scapulae and scalenius medius are required much less electrical intensity than other—3-7 mAmps.
[0134] There is a difference in treating MSI, like whiplash, and any RSI of the neck area. RSI is usually easier to locate because the injury has developed over a prolonged period of time, and injured muscles/muscles-threads are grouped together. Whiplash is more difficult to locate on palpation. Range of movement is more informative and helps to focus on more impaired muscles. Due to the excessive but short-time impact, muscle-threads get ruptured and the injury is wwidespread And, of course, it also depends on the power and direction of the impact, as well as the head position at impact time. Guidelines for these particular cases are the same but improvement is slower.
[0135] Carpal Tunnel Syndrome.
[0136] Carpal Tunnel is deep groove on the front of the carpal bones roofed with Transverse Carpal Ligamentand converted into a tunnel, through which the Flexor tendons of the digits and the median nerve pass. Symptoms of median nerve compression due reduced room at Carpal tunnel is called Carpal tunnel syndrome. The recent researches prove that thickened sheath of tendons is a one of key factors of the impairment. The reasons may be are sclerotic process and inflammation/edema. The sclerotic process of synovial layer is usually irreversible. The treatment is surgical. The treatment offered here is proved effective for Carpal tunnel syndrome related to repetitive strain injuries and on pre-surgical stage only.
[0137] Statistics tells that women have the problem more often than men. The common thing among women, when they have carpal tunnel syndrome on one hand, is that over a period of the time it occurs on the other hand. The time may vary from a few months to a few years. Often it correlates with pregnancy and edema, and as soon the pregnancy/edema is over, the symptoms disappear.
[0138] Chiropractic doctors believe than carpal tunnel syndrome develops due to a neck condition. Successful neck manipulation improves some patient's condition.
[0139] The treatment is based on the idea that carpal tunnel space reduces due inflammation/edema of belonging tissues like muscles and tendons. The carpal tunnel-syndrome may be also a manifestation of a distant injury of neck muscles/vertebra. Therefore the treatment area supposes include neck, arm and wrist. When electrical impulses are sent through the periosteum and lower motor neuron to the wrist the stimulation includes all three levels—osteotome, myotome, and neurotome. The application of a needle on affected vertebra, which is often C 4-5, and a patch on a base of palm, just below carpal tunnel support the requirements of the stimulation. The frequency is 2-3 Hz, intensity is 25-40 mAmps and the stimulation time is 10 min. Amount of required sessions relays on impairment age. The longer the patient delays the treatment the more sclerotic tissues build up, the more reasons to go for surgery than any conservative treatment.
[0140] Pain in the Sole.
[0141] This is a very common malady among runners and some ladies over 40 years of age. This injury is most often related to the flexor hallucis longus, as is presented as semi-tendinous muscle on the plantar surface. It goes from the big toe toward the calcaneus, by the medial side. Shortening of the tendon causes painful walking, as well as deviation of the big toe over a long period of time.
[0142] Treatment: applying a needle spinous process on L5, and another needle on the muscle. The best way for needling is to have foot at the dorsiflexion position. Stretch the muscle, and insert the needle at the most sensitive spot, making sure the needle has reached the spot. Let the patient gently relax the foot, connect the wires to the needle and and stimulate it for 7-10 minutes, at an intensity 20-30 milliamps and, a frequency of two Hz.
[0143] Injuries Related to Excessive Jogging.
[0144] Usually, athletes suffer calf pain. Palpation of the calf should be done when the foot is at the dorsiflexion position. Common area of injuries are:1) Back lateral/medial side of calf and 2) Lateral/media-lateral side of knee. The injured muscles usually are flexor hallucis longus, which may be combined with the flexor digitorum longus and tibialis posterior.
[0145] Treatment: The foot must be at the dorsiflexion position for flexors muscles, before treatment, at needling or palpation time. Position for the “vertebra”needle is S2 spinous process. The frequency is two to three Hz, intensity should be 25-30 milliamps, for seven to ten minutes for every muscle.
[0146] Knee Pain.
[0147] Muscle-related knee pain is usually found in the distal part of the vastus lateralis and vastus medialis. However, stimulation of the near-to-knee muscle part is complicated. The best way to do this is to insert the needle into the middle part of the muscle without paying attention to the sore-spot location. It is difficult to obtain efficient contraction from any near-to-knee muscle part.
[0148] The vertebra needle position is L3 spinous process. The frequency is two to three Hz, and the intensity is 25-30 milliamps. Time required for stimulation is seven to ten minutes. | A set of electrically induced muscle contractions serves the purpose of rapid recovery of muscle strain injury and related health problems such as low back pain and sciatica, upper neck pain and headache or dizziness etc. A single muscle contraction is induced by a single impulse between tips of two electrodes (acupuncture needles) by employing lower motor neuron path way. Such purpose performs by stationary placed of one needle on a vertebra (periosteum) and another one inside injured muscle. The impulse goes through dorsal root—lower motor neuron—muscle and induces whole muscle contraction. A set of such contractions with frequency between 1-2 Hz pumps blood and lymph through the tissue, makes greater the pressure gap between arterial and venous blood. Therefore reduced swelling, restored blood circulation and released from compression intramuscular nerve improve patient feelings on long term. Due to complexity of muscle strain injury author offers two additional treatments neurotome and osteotome electrical stimulation. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to containers for the storage and disposal of unwanted liquids such as waste oil that has been used in cooking or used engine oil that has been removed from automobiles during changing of the oil.
The disposal of waste oil such as cooking oil which has been used for deep frying, liquid fats, suspended greases and the like in homes and restaurants, or petroleum based lubricants such as engine oil that remains after changing the crankcase or gearbox oil in automobiles, presents several problems.
More specifically, the existence of waste oils in the home, business and industry presents the practical problem of immediate disposal into a container from which the oil will not inconveniently leak or spill on site or in transit to its final disposition. Moreover, if such waste oil is allowed to flow into sewer water, sewer pipes may become clogged producing a foul odor, and cause pollution problems in terms of contamination of rivers and other waterways. Disposal or leakage of waste oil, particularly toxic waste oil, into the soil can result in ground water contamination, among other things.
Therefore, various forms of technology have been proposed to provide a way to dispose of such waste oil.
For example, devices utilizing loose granular forms of absorbents had the problem of the fine particles being dispersed during manufacturing, distribution and usage, which resulted in the device being difficult to handle.
Other methods utilizing granular absorbents enclosed in numerous individual pouches which, although able to absorb waste oil, require substantial time to do so. Therefore, these methods have the fault of waste oil potentially leaking from the container after it is supplied but before it is absorbed by the absorbent material.
Moreover, absorbent materials in filamentary form could not be mechanically placed in the container and had to be manually inserted, which resulted in problems in mass production.
SUMMARY OF THE INVENTION
This invention is designed to solve the problems described above, by providing a waste liquid disposal container which is comprised of absorbent materials in the form of thick pads or mats which can sufficiently absorb such liquids. Preferably, these absorbent materials are in the form of a mat comprised of multiple pads superimposed on one another, having cavities formed between the superimposed absorbent materials to accept the liquid that is supplied to the inside of the container, all of which are enclosed by a receptacle made from material that is non-permeable and resistant to the liquid.
In a disposal container having the structure described above, the placement of the absorbent materials in the pouch during manufacture is easy as the absorbent materials are in the form of pads, which form absorbent mats. In addition, since the absorbent materials are able to sufficiently absorb waste oil and, since cavities are provided between each of the superimposed oil absorbent materials, preferably in the form of multiple, superimposed layers, even if a large volume of waste oil is supplied to the container all at once, the waste oil will be rapidly received within the cavities among the absorbant pads and will be effectively absorbed therefrom by the pads without leakage from the container.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective of an example of the absorbent material for use in this invention, first folded and then open.
FIG. 2 is a perspective of one embodiment of the container of this invention, having absorbent material contained within a receptacle.
FIG. 3 is a perspective of a variation of the embodiment of FIG. 2.
FIG. 4 is a perspective, partial cut-away of another embodiment of the invention.
FIG. 5 is a perspective, partial cut-away of a variation of the embodiment of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
The following provides a description of embodiments of the invention based on the drawings provided.
The container of FIG. 2 is comprised of oil absorbent material 2, which is contained in receptacle 1.
Receptacle 1 is made of an oil resistant material that is impervious to oil and other liquids. Therefore, when waste oil is supplied to the inside of the receptacle, such waste oil will not permeate through to the outside. The receptable can be a pouch made from a flexible, polymeric material, and can also have a resealable top (not shown) to facilitate repeated uses. Such resealable opening can be in the known form of interlocking grooves, forming a plastic zipper, or by use of a strip of a resealable adhesive applied on each of the opposing edges of the pouch at the mouth of the receptacle. Examples of materials that can be used for the receptacle include synthetic resins such as polyethylene, vinyl, and resin-laminated paper.
Oil absorbent material 2 is, preferably, made from a material which is sufficiently able to absorb oil and is in the form of one or more thick mats. The absorbent pads used to form these mats of absorbent material are shown in FIG. 1. Filamentary pulp 4, which is obtained from finely crushed particles of old paper and pulp, etc., made primarily from recycled waste paper, is laminated in the form of a pad by mechanical means and bonded onto a thin oil absorbent sheet 3, which is made from a material such as paper or nonwoven fabric. This flexible, laminated structure is then folded over several times upon itself, as shown at the top of FIG. 1.
Absorbent material 2 is contained in receptacle 1 in the form of a multiple number of pads superimposed on each other, as shown in FIG. 2. Cavities 5, which are formed between the mats of oil absorbent material 2, initially contain the waste oil when it is supplied to the inside of receptacle 1.
Absorbent material 2 is shown in FIGS. 2 and 3 in the form of thick mats formed by the folding of the pads of thin layers of filamentary pulp 2, laminated onto oil absorbent sheets 3. Multiple absorbent materials 2 may be horizontally superimposed on each other as shown in FIG. 2, vertically superimposed on each other as shown in FIG. 3 or otherwise configured in abutting or parallel relationship to one another. The mat of absorbent materials 2 may also be comprised of a single, long pad of absorbent materials 2, folded several times upon itself, or may be made from several single sheets of absorbent material 2 placed adjacent to one another in the receptacle 1. In the latter case, the single sheets of absorbent material 2 may be formed in different lengths which are alternately placed adjacent to one another to form cavities similar to the cavities 5 formed by the folds in absorbent material 2, as shown in FIGS. 2 and 3.
When waste oil or other liquid is introduced into receptable 1, a portion of such liquid is directly absorbed by absorbent material 2 and the remaining portion of such liquid, which cannot be immediately absorbed, enters along the inside surface of receptacle 1 and becomes contained in cavities 5. The liquid contained in cavities 5 is gradually absorbed by absorbent materials 2, avoiding leakage or spillage thereof from receptacle 1 which might otherwise occur if the structure of the container permitted the introduced liquid to remain at or near the opening of the receptacle.
In FIGS. 4 and 5, a containment frame 6 is provided in the interior of receptacle 1 which serves to stabilize oil absorbent material 2 and the container during manufacturing, distribution and use. The structure of the containment frame, particularly openings 7, also allows a large volume of waste oil to be introduced into the container at once, which has the advantages previously discussed.
The containment frame 6 shown in FIGS. 4 and 5 has a hollow structure in which flow-through openings 7 are formed in the top and sides. Such flow-through openings may be of any shape or configuration or, alternatively, the containment frame may be in the form of a net-like or other structure which does not prohibit the flow of liquid therethrough. Containment frame 6 also serves to surround and maintain absorbent material 2 in the preferred configuration of superimposed layers.
This structure of a containment frame enables the remaining portion of such liquid not directly absorbed by absorbent material 2 to penetrate into the hollow portion through the flow-through openings on the upper surface of containment frame 6, where it is then stored. Moreover, liquid is also absorbed by absorbent material 2 or trapped in cavities 5, after passing through the openings 7 on the lateral surfaces of containment frame 6.
When absorbent material 2 extends above the upper surface of containment frame 6, it can obstruct the flow-through sections on the upper surface of containment frame 6, making it difficult for liquid to penetrate into the hollow areas. In addition, if the upper surface of absorbent material 2 does not reach to the upper surface of containment frame 6, the flowthrough openings of the lateral surfaces of containment frame 6, which are located above absorbent material 2, lose their significance. Therefore, it is preferred that the upper surface of absorbent material 2 and the upper surface of containment frame 6 be at nearly the same height.
As shown in FIGS. 4 and 5, containment frame 6 is provided in the form of a crossing structure, forming four sections 8. When absorbent material 2 is placed in the sections 8 that are formed by this crossing structure of containment frame 6, effective absorption of waste liquid can be achieved. A multiple number of absorbent materials can be either horizontally superimposed on one another, as shown in FIG. 4, or vertically superimposed on one another, as shown in FIG. 5.
A box 9 is shown in FIGS. 4 and 5 which, if receptacle 1 is a pouch or otherwise made of a flexible material, stabilizes receptacle 1 and prevents it from being tipped over and having its contents spilled out.
Waste oil can be absorbed with substantially enhanced efficacy as a result of using a multiple number of the above mats and mechanically folding them over two or three times on top of each other to form a structure in which the mats are superimposed on top of each other, thereby forming cavities between the folded mats of the absorbent material, even if a large volume of waste oil is supplied all at once into the pouch. The surface area on which oil is absorbed is increased due to the waste oil being stored in the above cavities, and the absorption efficiency of the container is thereby greatly improved. This results in effective absorption of waste oil without any leakage of waste oil from the receptacle and, in some embodiments, also without great risk of tipping over of the container after the waste liquid has been supplied.
Therefore, this invention has a high degree of practical value for reasons that include ease of disposal of waste oil, avoidance of problems relating to environmental pollution, and a simple having the capability of being mass produced at a low cost.
It will be understood that the invention is not limited to the preferred illustrations and embodiments described above, but also encompasses the subject matter delineated by the following claims and all equivalents thereof. | A container for the storage and disposal of liquids, such as liquid fats, oils and suspended greases, comprising a receptacle with interior walls impervious and resistant to such liquids and, contained within the receptacle, material capable of absorbing such liquids which is comprised of one or more pads of absorbent material, such as paper or other fibrous or filamentary pulp products, aligned in adjacent planes, whereby a plurality of cavities is formed in the container to accept liquid introduced to the container for absorption by the absorbent material. | 1 |
CROSS REFERENCE TO RELATED PROVISIONAL APPLICATION
This application claims the benefit under 35 USC §119(e) of U.S. Provisional Application Ser. No. 60/034,932 filed Jan. 13, 1997, which is hereby incorporated by reference.
FIELD OF THE INVENTION
This invention relates to projection lens systems for use in projection televisions and, in particular, to color corrected, wide field of view, high numerical aperture projection lens systems for use with cathode ray tubes (CRTs) having curved faceplates.
BACKGROUND OF THE INVENTION
Various color-corrected high image quality lenses for use in high definition TV displays (HDTV) and in the projection of data and graphics are known in the art. These lenses are most frequently used in "front screen" two piece systems, i.e. systems where the projector and the screen are two different units. As a result of the long distance between the projector and the screen, most of the lenses used in such systems have a half field of view of under 30°.
In recent years, one piece projection TVs have become increasingly popular. These systems utilize a "rear screen" configuration in which the image is projected onto the rear surface of a translucent screen which is combined with the projector into a single unit. To achieve a small overall size for such systems, the lens must have a field of view as wide as possible.
To help achieve this goal and to provide for an increased amount of light at the outer portions of the image, CRTs having curved faceplates are most often used in this application. The faceplates of such CRTs are plano-convex shaped with the phosphor being deposited onto the curved side of the faceplate. As a result, the outer portion of the phosphor side of the faceplate curves towards the lens.
Presenting the CRT image on a surface concave towards the projection lens allows the lens to achieve a half field of view in excess of 40° and, in some cases, in excess of 45°. However the control of electron beam spot size on a curved phosphor surface is much more difficult than on a flat surface. Spot size control is important since a small and well controlled spot size is required to produce a high quality image.
As long as spot size was fairly large, projection lenses did not need to be corrected for axial color. However, since the introduction of digital TV (e.g., satellite TV and DVD), the quality level of one piece rear projection TV sets for consumer use has been significantly raised.
Manufacturers of such systems are now more willing to use more complicated electronics to minimize and control the size of the spot on a curved phosphor surface, e.g., they are willing to produce spot sizes whose sizes are 0.15 millimeters or less. Consequently, new high quality wide field of view large aperture lenses are needed to compliment the higher quality outputs of curved phosphor CRTs. As with the optics used in data and graphics projection TV systems, these new lenses need to be corrected for color.
A typical color corrected lens used with a flat faceplate CRT consists from long conjugate to short of a front weak aspherical unit, a main power unit which includes a color correcting doublet and a strong positive element having most of the power of the lens, a corrector unit following the main power unit and having at least one aspherical surface, and a strong negative power unit associated with the CRT faceplate and providing most of the correction for the field curvature of the lens.
From the image side, the main power unit typically has a negative element followed by a positive element of similar focal length but of opposite sign. These two elements provide color correction for the lens and their combined shape is typically meniscus towards the long conjugate. The single positive element providing most of the power of the lens usually follows the color correcting doublet.
In accordance with the present invention, it has been found that when the CRT faceplate is curved, the simultaneous correction of chromatic and monochromatic aberrations using commonly available glass is difficult to achieve when the leading element in the color correcting arrangement is negative and the overall shape of the color correcting doublet is meniscus towards the long conjugate of the lens. In particular, it has been found that the correction of lateral color is not good enough to obtain a sufficiently high level of image quality.
SUMMARY OF THE INVENTION
In view of the foregoing, it is an object of the present invention to provide a projection lens system which (1) has a large aperture, i.e., a f/number of about 1.2 or less, (2) has a wide field of view, i.e., a half field of view of at least 35°, and (3) provides a high level of correction of both chromatic and monochromatic aberrations when used with a curved phosphor CRT faceplate.
To achieve these and other objects, the invention provides a projection lens system which from long conjugate to short comprises a front lens unit (first lens unit; U1) comprising at least one aspherical element, a positive power lens unit (second lens unit; U2) providing most of the power of the lens system as well as correction of chromatic aberrations, a corrector lens unit (U CR ) comprising at least one aspherical element, and a strong negative power unit (third lens unit; U3) associated with the CRT faceplate having a strong concave surface facing the long conjugate and providing most of the correction of the field curvature of the lens. The positive power lens units of the invention are characterized in that they always have a positive element (L P ) on the long conjugate side of the unit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-5 are schematic side views of lens systems constructed in accordance with the invention.
FIG. 6 is a schematic diagram of a rear projection TV employing a lens system constructed in accordance with the invention.
The foregoing drawings, which are incorporated in and constitute part of the specification, illustrate preferred embodiments of the invention, and together with the description, serve to explain the principles of the invention. It is to be understood, of course, that both the drawings and the description are explanatory only and are not restrictive of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The lens systems of the invention preferably include a first lens unit, a second lens unit, a third lens unit, and a corrector lens unit wherein: 1) the first lens unit includes at least one aspherical surface; 2) the second lens unit (a) has a positive lens element at its long conjugate side, (b) provides color correction, and (c) has a strong positive optical power; 3) the third lens unit corrects for the field curvature of the lens system and has a relatively strong negative optical power; and 4) the corrector lens unit provides correction for, among other things, aberrations due to off-axis rays and has a relatively weak optical power.
The first lens unit serves to correct aperture type aberrations including spherical aberration and coma. As illustrated by the examples presented below, this unit can be composed of one or more lens elements. Preferably, the elements of this unit are composed of a plastic material.
The second lens unit preferably provides the majority of the lens system's positive optical power. This unit preferably includes three lens elements, namely, a positive first lens element preferably composed of glass, a second lens element preferably composed of glass which is preferably negative, but may also be positive, and a third lens element preferably composed of glass which has a power opposite to that of the second lens element. The first lens element of this unit is preferably the strongest positive lens element of the system and will be referred to hereinafter as the "positive power lens element." The second and third lens elements of this unit have appropriate optical dispersions and powers to provide axial color correction for the lens system.
The corrector unit and third lens unit serve to correct off-axis aperture dependent aberrations and field dependent aberrations, respectively. In particular, the corrector unit is effective in dealing with oblique spherical aberrations, while the third lens unit is effective in reducing the system's field curvature.
As illustrated by the examples presented below, the corrector lens unit can be composed of one or more lens elements. Preferably, the elements of this unit are composed of a plastic material.
The third lens unit is preferably composed of an aspherical plastic lens element which contacts the fluid which couples the lens system to the faceplate of the CRT. If desired, the aspherical plastic lens element of the third lens unit can include an absorptive color filter material in accordance with Wessling, U.S. Pat. No. 5,055,922.
Quantitatively, the ratio of the absolute value of the focal length (f 1 ) of the first lens unit to the overall focal length (f 0 ) of the projection lens is preferably greater than 2.5; the ratio of the focal length (f 2 ) of the second lens unit to the overall focal length of the projection lens is preferably less than 1.5; the ratio of the absolute value of the focal length (f CR ) of the corrector lens unit to the overall focal length of the projection lens is preferably greater than 2.0; and the ratio of the absolute value of the focal length (f 3 ) of the third lens unit to the overall focal length of the projection lens is preferably less than 2.5. The ratio of the focal length (f P ) of the positive power lens element of the second lens unit to the overall focal length of the projection lens is preferably less than 1.5.
FIGS. 1-5 illustrate various projection lenses constructed in accordance with the invention. Corresponding prescriptions appear in Tables 1-5. HOYA or SCHOTT designations are used for the glasses employed in the lens systems. Equivalent glasses made by other manufacturers can be used in the practice of the invention. Industry acceptable materials are used for the plastic elements.
The aspheric coefficients set forth in the tables are for use in the following equation ##EQU1## where z is the surface sag at a distance y from the optical axis of the system, c is the curvature of the lens at the optical axis, and k is a conic constant, which is zero except where indicated in the prescriptions of Tables 1-5.
The designation "a" associated with various surfaces in the tables represents an aspheric surface, i.e., a surface for which at least one of D, E, F, G, H, or I in the above equation is not zero. The designation "c" represents a conic surface, i.e., a surface for which k in the above equation is not zero. All dimensions given in the tables are in millimeters. The tables are constructed on the assumption that light travels from left to right in the figures. In actual practice, the viewing screen will be on the left and the CRT will be on the right, and light will travel from right to left.
The CRT faceplate constitutes surfaces 13-14 in FIG. 1, surfaces 15-16 in FIGS. 2 and 3, and surfaces 17-18 in FIGS. 4 and 5. A coupling fluid is located between surfaces 12-13 in FIG. 1, surfaces 14-15 in FIGS. 2 and 3, and surfaces 16-17 in FIGS. 4 and 5. The material designations for these components are set forth as six digit numbers in the tables, where a N e value for the material is obtained by adding 1,000 to the first three digits of the designation, and a V e value is obtained from the last three digits by placing a decimal point before the last digit.
In Table 1, the first lens unit comprises surfaces 1-2, the second lens unit comprises surfaces 3-8, the corrector lens unit comprises surfaces 9-10, and the third lens unit comprises surfaces 11-14.
In Table 2, the first lens unit comprises surfaces 1-2, the second lens unit comprises surfaces 3-8, the corrector lens unit comprises surfaces 9-12, and the third lens unit comprises surfaces 13-16.
In Table 3, the first lens unit comprises surfaces 1-4, the second lens unit comprises surfaces 5-10, the corrector lens unit comprises surfaces 11-12, and the third lens unit comprises surfaces 13-16.
In Tables 4 and 5, the first lens unit comprises surfaces 1-4, the second lens unit comprises surfaces 5-10, the corrector lens unit comprises surfaces 11-14, and the third lens unit comprises surfaces 15-18.
Table 6 summarizes various properties of the lens systems of the invention. As shown therein, the lens systems of Tables 1-5 have the various preferred properties referred to above. In this table, the designation "1/2 w" represents the half field of view of the lens system. With regard to color correction, the lens systems of Tables 1-5 achieve levels of lateral color correction of less than 0.15 millimeters at the phosphor screen for wavelengths from 480 nanometers to 640 nanometers, i.e., they achieve a level of color correction better than the spot size used for digital TV images.
FIG. 6 is a schematic diagram of a CRT projection television 10 constructed in accordance with the invention. As shown in this figure, projection television 10 includes cabinet 12 having projection screen 14 along its front face and slanted mirror 18 along its back face. Module 13 schematically illustrates a lens system constructed in accordance with the invention and module 16 illustrates its associated CRT tube. In practice, three lens systems 13 and three CRT tubes 16 are used to project red, green, and blue images onto screen 14.
Although specific embodiments of the invention have been described and illustrated, it is to be understood that a variety of modifications which do not depart from the scope and spirit of the invention will be evident to persons of ordinary skill in the art from the foregoing disclosure.
TABLE 1______________________________________Surf. Clear ApertureNo. Type Radius Thickness Glass Diameter______________________________________ 1 a 75.9254 9.00000 ACRYLIC 77.98 2 a 104.3505 13.19380 73.89 3 103.5327 18.00000 SK18 76.74 4 -109.7000 0.20000 76.79 5 763.8706 4.00000 SF13 73.78 6 75.6031 1.50000 71.30 7 76.0645 17.00000 SK18 72.99 8 -136.7573 2.51497 73.02 9 a -113.6070 8.00000 ACRYLIC 70.8410 a -175.9901 Space 1 68.8911 a -51.7837 4.00000 ACRYLIC 72.0512 -45.0000 10.00000 423500 78.1413 ∞ 13.00000 560500 130.0014 -350.0000 Image distance 130.00______________________________________Symbol Descriptiona - Polynomial asphereObject and Image Surface Surface Radius______________________________________ Image -350.0000______________________________________Even Polynomial AspheresSurf. No. D E F______________________________________ 1 -1.8029E - 06 -1.7193E - 09 -4.1653E - 13 2 -6.2849E - 07 -1.5207E - 09 -9.7477E - 14 9 3.5440E - 06 -1.5917E - 09 3.1581E - 1210 3.1798E - 06 1.9390E - 09 -6.2159E - 1211 -8.0531E - 06 1.6131E - 08 -3.3448E - 11______________________________________Surf. No. G H I______________________________________ 1 2.8754E - 16 2.7542E - 19 -1.1474E - 22 2 2.5200E - 16 3.4831E - 19 -1.6022E - 22 9 -4.1931E - 15 2.5658E - 18 -5.7526E - 2210 8.6420E - 15 -5.8716E - 18 1.5947E - 2111 3.6979E - 14 -2.1050E - 17 4.6654E - 21______________________________________Variable SpacesZoom Space 1 Focal ImagePos. T(10) Shift Distance______________________________________1 31.031 -0.681 0.0002 30.366 -0.337 0.000______________________________________First-Order Data______________________________________f/number 1.24 1.23Magnification -0.1167 -0.1013Object Height -584.20 -673.10Object Distance -731.56 -835.05Effective Focal Length 76.679 77.021Image Distance 0.00 0.00Overall Length 863.00 965.82Forward Vertex Distance 131.44 130.77Barrel Length 131.44 130.77Stop Surface Number 3 3Distance to Stop 4.70 4.70Stop Diameter 76.829 76.300Entrance Pupil Distance 24.312 24.312Exit Pupil Distance -67.640 -67.279______________________________________First Order Properties of ElementsElement SurfaceNumber Numbers Power f'______________________________________1 1 2 0.19569E - 02 511.002 3 4 0.11643E - 01 85.8913 5 6 -0.88817E - 02 -112.594 7 8 0.12711E - 01 78.6755 9 10 -0.14753E - 02 -677.816 11 12 0.17176E - 02 582.207 12 13 -0.94067E - 02 -106.318 13 14 0.16000E - 02 625.006 8 11 14 -0.60935E - 02 -164.11______________________________________Element SurfaceNumber Numbers lpp l'pp______________________________________1 1 2 -14.568 -20.0232 3 4 5.5065 -5.83463 5 6 2.5473 0.252124 7 8 3.8212 -6.87025 9 10 -10.185 -15.7776 11 12 17.107 14.8667 12 13 0.33015E - 07 -7.02598 13 14 8.3333 0.33458E - 066 8 11 14 -5.4074 -24.177______________________________________
TABLE 2______________________________________Surf. Clear ApertureNo. Type Radius Thickness Glass Diameter______________________________________ 1 a 78.1234 9.00000 ACRYLIC 80.44 2 ac 95.7568 12.51433 73.44 3 100.9258 18.00000 SK18 74.89 4 -100.9258 0.20000 74.76 5 -170.2562 4.00000 SF4 72.53 6 156.9671 0.19835 70.96 7 162.8714 16.00000 SK18 70.98 8 -82.6935 0.20000 71.35 9 a 58.9473 6.00000 ACRYLIC 68.6610 a 42.6679 10.59490 66.5811 a -351.9562 10.00000 ACRYLIC 66.6312 c -79.5372 Space 1 68.7013 a -40.0417 4.00000 ACRYLIC 73.0814 -45.0000 9.00000 423500 78.2715 ∞ 14.10000 563500 130.0016 -350.0000 Image distance 130.00______________________________________Symbol Description a - Polynomial asphere c - Conic section Object and Image Surface Surface Radius______________________________________ Image -350.0000______________________________________Conics Surface Number Constant______________________________________ 2 2.3606E + 00 12 -3.9930E + 00______________________________________Even Polynomial AspheresSurf. No. D E F______________________________________ 1 -8.8369E - 07 -5.2235E - 10 -2.4140E - 13 2 9.2707E - 08 -4.8079E - 11 1.3624E - 14 9 -6.4344E - 06 3.1413E - 09 -4.3581E - 1310 -6.8817E - 06 4.6463E - 09 -8.8108E - 1211 1.7262E - 06 -3.7483E - 09 1.0024E - 1113 -4.5889E - 06 1.6253E - 08 -3.1557E - 11______________________________________Surf. No. G H I______________________________________ 1 1.9448E - 16 -1.4562E - 19 4.1180E - 23 2 8.0193E - 18 -9.5624E - 22 -2.8791E - 24 9 -5.6950E - 16 1.2426E - 19 1.5610E - 2210 1.3192E - 14 -1.0078E - 17 2.8873E - 2111 -1.4338E - 14 1.0363E - 17 -3.1241E - 2113 3.6166E - 14 -2.2102E - 17 5.6074E - 21______________________________________Variable SpacesZoom Space 1 Focal ImagePos. T(12) Shift Distance______________________________________1 22.731 -0.184 0.0002 22.012 0.022 0.000______________________________________First-Order Data______________________________________f/number 1.24 1.23Magnification -0.1167 -0.1013Object Height -584.20 -673.10Object Distance -726.46 -831.18Effective Focal Length 75.972 76.515Image Distance -.10075E - 03 -.10962E - 03Overall Length 863.00 967.00Forward Vertex Distance 136.54 135.82Barrel Length 136.54 135.82Stop Surface Number 3 3Distance to Stop 14.41 14.41Stop Diameter 74.623 74.260Entrance Pupil Distance 30.585 30.585Exit Pupil Distance -63.002 -62.702______________________________________First Order Properties of ElementsElement SurfaceNumber Numbers Power f'______________________________________1 1 2 0.13603E - 02 735.152 3 4 0.12265E - 01 81.5313 5 6 -0.93753E - 02 -106.664 7 8 0.11395E - 01 87.7615 9 10 -0.28066E - 02 -356.306 11 12 0.48635E - 02 205.617 13 14 -0.99642E - 03 -1003.68 14 15 -0.94067E - 02 -106.319 15 16 0.16086E - 02 621.677 9 13 16 -0.87876E - 02 -113.80______________________________________Element SurfaceNumber Numbers lpp l'pp______________________________________1 1 2 -22.840 -27.9952 3 4 5.6815 -5.68153 5 6 1.1752 -1.08354 7 8 6.6346 -3.36855 9 10 16.562 11.9886 11 12 8.5453 1.93117 13 14 -29.488 -33.1408 14 15 0.33015E - 07 -6.32339 15 16 9.0211 0.66198E - 067 9 13 16 -3.7644 -22.465______________________________________
TABLE 3______________________________________Surf. Clear ApertureNo. Type Radius Thickness Glass Diameter______________________________________ 1 a 75.3275 9.00000 ACRYLIC 85.75 2 a 101.5103 13.04334 81.71 3 a -78.2772 9.00000 ACRYLIC 81.53 4 a -65.4519 0.50000 81.19 5 64.9785 22.70542 BACD18 81.02 6 -199.5574 0.50000 78.41 7 -10067.2405 4.00000 FD10 76.03 8 64.8920 0.40460 72.14 9 63.6521 14.00000 SK5 72.6410 699.7213 3.77308 71.9711 a -206.2623 9.00000 ACRYLIC 71.6912 a -101.9762 Space 1 70.0213 a -50.2233 4.00000 ACRYLIC 72.2314 -44.5060 10.00000 423500 77.6015 ∞ 13.00000 560500 130.0016 -350.0000 Image distance 130.00______________________________________Symbol Descriptiona - Polynomial asphereObject and Image Surface Surface Radius______________________________________ Image -350.0000______________________________________Even Polynomial AspheresSurf. No. D E F______________________________________ 1 -1.4648E - 06 -7.1777E - 10 -8.2347E - 13 2 -4.7680E - 07 -6.5540E - 10 -3.8711E - 13 3 1.0442E - 06 2.4385E - 10 -3.8441E - 15 4 9.4890E - 07 -4.6092E - 10 2.3843E - 1311 2.8701E - 07 -6.9913E - 10 2.9784E - 1212 6.9145E - 07 2.8489E - 09 -5.2728E - 1213 -5.0308E - 06 4.0069E - 09 -3.3618E - 12______________________________________Surf. No. G H I______________________________________ 1 8.2100E - 18 3.0400E - 19 -7.5061E - 23 2 1.4985E - 16 2.7016E - 19 -9.5863E - 23 3 8.5613E - 17 3.0480E - 20 -2.1414E - 23 4 -1.6869E - 17 -4.2323E - 20 1.3611E - 2311 -3.4379E - 15 2.0972E - 18 -5.2091E - 2212 8.0919E - 15 -5.6980E - 18 1.6113E - 2113 6.1594E - 16 3.2548E - 19 -2.9596E - 22______________________________________Variable SpacesZoom Space 1 Focal ImagePos. T(12) Shift Distance______________________________________1 25.084 -0.336 -0.0102 24.416 -0.089 -0.010______________________________________First-Order Data______________________________________f/number 1.14 1.13Magnification -0.0935 -0.0794Object Height -730.00 -860.00Object Distance -911.87 -1065.1Effective Focal Length 78.321 78.691Image Distance -.97413E - 02 -.98614E - 02Overall Length 1049.9 1202.4Forward Vertex Distance 138.00 137.33Barrel Length 138.01 137.34Stop Surface Number 5 5Distance to Stop 10.10 10.10Stop Diameter 83.304 82.839Entrance Pupil Distance 35.323 35.323Exit Pupil Distance -63.176 -62.798______________________________________First Order Properties of ElementsElement SurfaceNumber Numbers Power f'______________________________________1 1 2 0.18829E - 02 531.102 3 4 0.15228E - 02 656.703 5 6 0.12644E - 01 79.0894 7 8 -0.11391E - 01 -87.7905 9 10 0.85153E - 02 117.446 11 12 0.25180E - 02 397.147 13 14 0.15551E - 02 643.068 14 15 -0.95111E - 02 -105.149 15 16 0.16000E - 02 625.007 9 13 16 -0.63626E - 02 -157.17______________________________________Element SurfaceNumber Numbers lpp l'pp______________________________________1 1 2 -15.565 -20.9762 3 4 29.849 24.9583 5 6 3.5160 -10.7984 7 8 2.2912 -0.14769E - 015 9 10 -0.87320 -9.59906 11 12 11.586 5.72817 13 14 19.104 16.9308 14 15 -0.34014E - 07 -7.02599 15 16 8.3333 0.33458E - 067 9 13 16 -5.1858 -23.948______________________________________
TABLE 4______________________________________Surf. Clear ApertureNo. Type Radius Thickness Glass Diameter______________________________________ 1 a 90.0535 10.00000 ACRYLIC 105.96 2 a 102.8973 15.78776 97.56 3 a -70.2250 9.00000 ACRYLIC 97.45 4 a -95.4074 0.50000 101.18 5 92.3723 27.00000 SK18 109.04 6 -642.6984 0.20000 106.50 7 158.4645 20.00000 SK18 98.88 8 -158.4645 0.06179 95.59 9 -157.2990 6.00000 SF6 95.5510 498.4189 6.57092 89.5511 a -372.6684 9.00000 ACRYLIC 92.3512 a -395.7785 1.50000 92.4113 a 172.5227 10.00000 ACRYLIC 92.4214 a -445.8306 Space 1 94.0215 a -59.4571 5.60000 ACRYLIC 99.7116 -60.5000 12.00000 430500 107.6317 ∞ 14.00000 565500 180.0018 -600.0000 Image distance 180.00______________________________________Symbol Descriptiona - Polynomial asphereObject and Image Surface Surface Radius______________________________________ Image -599.9999______________________________________Even Polynomial AspheresSurf. No. D E F______________________________________ 1 -9.4817E - 07 -1.0331E - 10 -1.3133E - 13 2 -6.9575E - 07 -2.7955E - 10 2.6820E - 14 3 2.3978E - 06 -8.0746E - 11 -1.7129E - 14 4 2.2527E - 06 -2.4454E - 10 3.9267E - 1411 1.8502E - 06 -1.5291E - 10 -4.9911E - 1412 7.5312E - 07 9.9338E - 11 -7.2778E - 1513 -1.3285E - 06 -3.6881E - 10 4.5883E - 1314 -1.6576E - 07 4.4703E - 10 -1.1777E - 1215 -2.0474E - 06 1.8685E - 09 -1.0171E - 12______________________________________Surf. No. G H I______________________________________ 1 7.7524E - 18 2.2028E - 20 -3.9483E - 24 2 2.6395E - 17 1.2925E - 20 -4.2776E - 24 3 2.2515E - 17 3.9252E - 21 -3.6813E - 24 4 -8.9174E - 18 -7.2170E - 21 1.0728E - 2411 1.1640E - 17 5.4479E - 21 -1.8530E - 2412 -6.3377E - 18 -1.7516E - 21 -2.6170E - 2413 -3.8744E - 16 1.6036E - 19 -2.3489E - 2314 9.4904E - 16 -3.3734E - 19 5.1496E - 2315 1.5162E - 16 6.1179E - 20 -2.0252E - 23______________________________________Variable SpacesZoom Space 1 Focal ImagePos. T(14) Shift Distance______________________________________1 40.761 0.936 0.0002 40.092 1.143 0.000______________________________________First-Order Data______________________________________f/number 1.17 1.16Magnification -0.1035 -0.0931Object Height -914.40 -1016.0Object Distance -1076.0 -1189.3Effective Focal Length 100.80 101.25Image Distance -.37074E - 03 -.44262E - 03Overall Length 1264.0 1376.6Forward Vertex Distance 187.98 187.31Barrel Length 187.98 187.31Stop Surface Number 5 5Distance to Stop 21.49 21.49Stop Diameter 107.586 107.618Entrance Pupil Distance 45.852 45.852Exit Pupil Distance -80.038 -79.740______________________________________First Order Properties of ElementsElement SurfaceNumber Numbers Power f'______________________________________ 1 1 2 0.86056E - 03 1162.0 2 3 4 -0.16366E - 02 -611.01 3 5 6 0.78262E - 02 127.78 4 7 8 0.78942E - 02 126.68 5 9 10 -0.68246E - 02 -146.53 6 11 12 -0.67408E - 04 -14835. 7 13 14 0.39484E - 02 253.27 8 15 16 0.11095E - 03 9013.3 9 16 17 -0.71074E - 02 -140.7010 17 18 0.94167E - 03 1061.9 8 10 15 18 -0.61289E - 02 -163.16______________________________________Element SurfaceNumber Numbers lpp l'pp______________________________________ 1 -37.330 -42.654 2 3 4 -19.052 -25.885 3 5 6 2.0973 -14.593 4 7 8 6.2468 -6.2468 5 9 10 0.79080 -2.5057 6 11 12 -111.51 -118.43 7 13 14 1.8778 -4.8526 8 15 16 275.78 280.62 9 16 17 0.27398E - 07 -8.391610 17 18 8.9457 -0.23553E - 06 8 10 15 18 -3.8740 -25.497______________________________________
TABLE 5______________________________________Surf. Clear ApertureNo. Type Radius Thickness Glass Diameter______________________________________1 a 118.1397 10.00000 ACRYLIC 105.092 a 138.7672 12.76842 97.783 a -64.2610 9.00000 ACRYLIC 96.914 a -87.7383 1.00000 94.285 87.6633 30.00000 SK18 103.106 -174.5638 0.30242 101.327 -168.9595 6.00000 SF6 101.268 261.3135 1.00000 97.539 95.6146 20.66778 SK5 96.9610 -260.0801 1.00000 96.1211 a -730.9406 9.00000 ACRYLIC 94.2612 a 395.7578 4.82062 90.4513 a 114.6574 10.00000 ACRYLIC 90.8714 a 853.3167 Space 1 92.4415 a -59.7301 5.60000 ACRYLIC 96.2116 -58.5000 12.00000 430500 105.2017 ∞ 14.60000 565500 180.0018 -600.0000 Image distance 180.00______________________________________Symbol Descriptiona - Polynomial asphereObject and Image Surface Surface Radius______________________________________ Image -599.9999______________________________________Even Polynomial AspheresSurf. No. D E F______________________________________ 1 -6.1424E - 07 -1.2999E - 10 -1.1135E - 13 2 -5.5851E - 07 -3.4414E - 10 -1.1712E - 15 3 2.7572E - 06 -1.7060E - 11 -6.1786E - 14 4 2.5873E - 06 2.0009E - 11 9.8026E - 1511 1.5098E - 06 -1.5395E - 10 3.5089E - 1412 2.4066E - 07 2.0670E - 10 5.5166E - 1413 -1.0005E - 06 -6.5093E - 10 4.8030E - 1314 4.8019E - 07 3.0152E - 10 -1.2475E - 1215 -2.2995E - 06 1.5448E - 09 -9.4063E - 13______________________________________Surf. No. G H I______________________________________ 1 8.7573E - 18 2.1148E - 20 -3.9525E - 24 2 2.8706E - 17 1.5666E - 20 -4.9291E - 24 3 1.6863E - 17 4.2845E - 21 -2.1224E - 24 4 -2.9054E - 17 -2.1846E - 21 1.4343E - 2411 2.1688E - 17 -1.6169E - 22 -3.6426E - 2412 3.1063E - 17 1.0689E - 20 -5.7969E - 2413 -3.5518E - 16 1.6480E - 19 -2.4355E - 2314 9.6934E - 16 -3.2272E - 19 4.3847E - 2315 1.7519E - 16 5.4265E - 20 -2.5406E - 23______________________________________Variable SpacesZoom Space 1 Focal ImagePos. T(14) Shift Distance______________________________________1 42.527 -0.300 0.0002 43.133 -0.584 0.000______________________________________First-Order Data______________________________________f/number 1.22 1.23Magnification -0.0931 -0.1035Object Height -1016.0 -914.40Object Distance -1194.7 -1080.6Effective Focal Length 101.87 101.46Image Distance -.10580E - 03 -.12529E - 03Overall Length 1385.0 1271.5Forward Vertex Distance 190.29 190.89Barrel Length 190.29 190.89Stop Surface Number 5 5Distance to Stop 24.86 24.86Stop Diameter 100.393 100.501Entrance Pupil Distance 44.371 44.371Exit Pupil Distance -80.781 -81.051______________________________________First Order Properties of ElementsElement SurfaceNumber Numbers Power f'______________________________________ 1 1 2 0.72085E - 03 1387.2 2 3 4 -0.17955E - 02 -556.93 3 5 6 0.10498E - 01 95.259 4 7 8 -0.79691E - 02 -125.49 5 9 10 0.82768E - 02 120.82 6 11 12 -0.19283E - 02 -518.60 7 13 14 0.37446E - 02 267.05 8 15 16 0.43541E - 03 2296.7 9 16 17 -0.73504E - 02 -136.0510 17 18 0.94167E - 03 1061.9 8 10 15 18 -0.60528E - 02 -165.21______________________________________Element SurfaceNumber Numbers lpp l'pp______________________________________ 1 -33.045 -38.815 2 3 4 -18.884 -25.784 3 5 6 6.3964 -12.737 4 7 8 1.2917 -1.9978 5 9 10 3.5681 -9.7055 6 11 12 3.8984 -2.1107 7 13 14 -1.0345 -7.6991 8 15 16 72.674 71.177 9 16 17 0.24994E - 07 -8.391610 17 18 9.3291 0.52548E - 06 8 10 15 18 -4.0041 -26.032______________________________________
TABLE 6______________________________________Ex.No. f.sub.0 f.sub.1 f.sub.2 fcr f.sub.3 fp 1/2 w______________________________________1 76.68 511.00 67.32 -677.81 -164.11 85.89 38.0°2 75.97 735.15 72.59 464.15 -113.80 81.53 38.0°3 78.32 310.32 97.32 397.14 -157.17 79.09 38.0°4 100.80 -1387.72 106.18 255.53 -163.16 127.78 39.3°5 101.46 -968.64 94.73 537.97 -165.21 95.26 39.3°______________________________________ | A projection television system (10) is provided which has a CRT (16) with a curved faceplate and a projection lens system (13) for forming an image on a screen (14). The projection lens system (13) is characterized by a power lens unit (U2) which (a) provides color correction for the lens system and (b) has two positive lens elements and a negative lens element with one of said positive lens elements (L P ) being at the image side of the unit. The positive lens element (L P ) at the image side of the second lens unit (U2) is preferably the strongest positive lens element in the lens system, having a focal length (f P ) which is less than 1.5 times the focal length of the system (f 0 ). | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a self-cancelling mechanism for cancelling a turn-signal switch of a vehicle put in an actuated condition in response to a steering operation of the vehicle.
2. Description of the Prior Art
A turn-signal switch mounted on a steering column of a vehicle functions to actuate turn-signal lamps, for example right side turn-signal lamps, to signal a change of a running direction of the vehicle to succeeding vehicles and the like by a driver's operation of a turn-signal lever prior to the rotation of a steering wheel of the vehicle.
After this, the driver rotates the steering wheel to the right side to change the running direction of the vehicle. When the change of the running direction is completed, the steering wheel is returned back to its neutral position and by this return action, namely the rotation of the steering wheel in a cancelling direction, a self-cancelling mechanism acts to return the turn-signal switch back to a neutral position so that the turn-signal lamps are switched off.
In such a self-cancelling mechanism, in general, a ratchet is mounted on a bracket rotated by the turn-signal lever and is relatively movable to the bracket in a predetermined distance, and the ratchet is moved into a rotation locus of a cancelling cam which is rotated together with a steering shaft of the vehicle at the time of the rotation of the turn-signal lever so that the turn-signal lever is returned back to the neutral position by the rotation of the steering shaft in a cancelling direction.
In addition, when the steering wheel is rotated in the direction reverse to the cancelling direction with actuated, or blinking, turn-signal lamps the ratchet is relatively moved to the bracket so that the bracket is maintained in its rotation position and the turn-signal lamps are kept in their blinking condition. This relative movement is cancelled when the cancelling cam is separated from the ratchet, and the ratchet is returned back to its original position by a returning force of a return spring. By this returning force the ratchet is caused to strike against the bracket and striking noises occur continuously due to the rotation of the steering wheel in an anti-cancelling direction.
For this reason, for example, U.S. Pat. NO. 4,335,284 has proposed a turn-signal switch in which shock absorbing members are provided between a ratchet and a bracket.
In this switch, however, the shock absorbing members absorb kinetic energy of the ratchet but the ratchet still strikes against the bracket in the same manner as the conventional arts whereby the striking noises occur.
SUMMARY OF THE INVENTION
In a self-cancelling mechanism according to the present invention, a ratchet opposed to a cancelling cam body which is rotated together with a steering shaft is pivotally supported to a bracket, being rotatable from its neutral position to a pair of rotation positions, and is forced to the neutral position by an elastic member.
Accordingly, even when the ratchet is returned from one of the rotation positions back to the neutral position in response to the rotation of the steering shaft, the ratchet does not strike against the bracket so that striking noises do not occur.
Description will hereinunder be given of embodiments of the present invention with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 through 3 show one embodiment according to the present invention:
FIG. 1 is a plan view;
FIG. 2 is a cross sectional view; and
FIG. 3 is a disassembled perspective view of an enlarged main portion:
FIG. 4 is a perspective view of an enlarged main portion of a second embodiment;
FIG. 5 is a perspective view of an enlarged main portion of a third embodiment;
FIG. 6 is a perspective view of an enlarged main portion of a fourth embodiment; and
FIG. 7 is a perspective view of an enlarged main portion of a fifth embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the first embodiment of the present invention, as shown in FIGS. 1 and 2, a steering column is provided in its axial center portion with a steering shaft S1 passing through a column tube S2 and the forward end of the steering shaft S1 is securely provided with a steering wheel S3 for operation of a driver.
Fixed to the column tube S2 is a switch-mounting base plate 1 through steel plate S4 by screws or the like. The forward end of the cylindrical portion 2 of the base plate 1 is provided with a cancelling cam body 3, which is rotatable about the cylindrical portion 2. Projected from the peripheral portion of the cancelling cam body 3 towards the radius direction of the cam body 3 are a pair of projections 3a and projected from the cancelling cam body 3 towards the axis direction thereof are three projections 3b. The projections 3b are caused to engage with engaging holes, not shown, of the steering wheel S3 by the spring force of a compression coil spring 4 so that the cancelling cam body 3 is rotated together with the steering wheel S3.
The base plate 1 is formed with a through-hole 1a to which a bracket 5 is rotatably supported at its cylindrical portion 5a parallel to the steering shaft S1, and the bracket 5 is provided at its end portion on the cancelling cam body 3 side with a supporting recess 5b opened in the direction of the cancelling cam body 3 and being parallel substantially to the base plate 1 (refer to FIG. 3). The bracket 5 is formed with a pair of slit grooves 5c parallel to one another and between the slit grooves 5c, 5c single-supported beams 5d are formed. The single-supported beams 5d are flexible and are penetratingly formed close to their forward end with shaft holes 5e. The ratchet 6 is formed with co-axial shaft portions 6a, 6a which extend a space formed between a pair of the single-supported beams 5d, utilizing the elastic force of the beams 5d themselves, so that the shaft portions 6a, 6a are inserted into the shaft holes 5 e, 5e. The ratchet 6 is projectingly formed at its cancelling cam body 3 side with a pair of rectangular nail portions 7, 8 in a form of surrounding the shaft portions 6a. The nail portions 7, 8 are arranged close to the cam projections 3a of the cancelling cam body 3 for returning the bracket 5. In addition, the ratchet 6 is formed at its lower face with an arc recess 6b and the bracket 5 is formed with an arc recess, or groove, 5f having a sectional view of a semi-circle and opposed to the arc recess, or groove, 6b. Received in both of the arc recesses 6b and 5f is a compression coil spring 9, as being an elastic member, in a form of covering the recesses 6b and 5f. That is, the compression coil spring 9 is received on halves in the boundary of its axial center in the respective recesses 6b and 5f. The ratchet 6 is always kept in a neutral position, shown in FIG. 1, about the shaft portions 6a against the bracket 5 by the compression coil spring 9.
Opposed to the tip end of the bracket 5 is a detent wall 10 which is formed integrally on the base plate 1 and is provided with three recesses 10a through 10c in series. In addition, the bracket 5 is formed at its tip end with a blind hole 5g in which a ball 11 which engages with the recess 10a to 10c and a coil spring 12 which forces the ball 11 in the direction of the recesses 10a to 10c are provided. The condition that the ball 11 is forced into the central recess 10b is a neutral condition of the bracket 5 and a stopper, not shown, is provided so as to restrict the rotation of the bracket 5 within the range where the ball 11 is inserted into the recesses 10a to 10c.
The bracket 5 is formed at its forward end with a connecting recess 5h. Arranged on the base plate 1 close to the detent wall 10 is a knob holder 13 provided with shaft portions 13a, 13b and arranged on the upper face of the end portion of the base plate 1 is a trim panel 14 provided with recesses 14a, 14b, the knob holder 13 being rotatably supported to the recesses 14a and 14b through the shaft portions 13a and 13b. Rotatably supported to the knob holder 13 is a knob 16 through a pin 15. The forward end of the knob 16 is elongated from the trim panel 14 for operation of the driver. The knob holder 13 is formed at its lower end portion with a connecting projection 13c which is engaged with and connected to the connecting recess 5h.
Fixed to the base plate 1 is a dimmer and passing switch 17, an operating button 18 of which is caused to abut on an operation portion 16a of the knob 16 by a return spring 19, and the knob 16 is always forced in the direction of an arrow mark A by the return spring 19. Furthermore, the dimmer and passing switch 17 is switched by the repeatedly pushing operation of the operation button 18. On the other hand, fixed to the base plate 1 is a turn-signal switch 20, and connected to a connecting portion 13d of the lower end of the knob holder 13 is a contact holder 21 which receives a driving force from the knob holder 13. Supported on the contact holder 21 is a movable contact 21a, which is moved in a direction of a right angle to FIG. 2 to be caused to contact with a plurality of fixed contacts 21b selectively whereby turn-signal lamps on the right side or the left side of the vehicle are actuated.
The dimmer and passing switch 17, the base plate 1 and the trim panel 14 are fixed integrally by a screw 22.
Description will now be given of operation of the present embodiment.
As shown in FIGS. 1 and 2, when the knob 16 is placed in the neutral position, the turn-signal switch 20 is also put in the neutral position. At this time the nail portions 7, 8 of the ratchet 6 is positioned out of the rotation locus of the cam projections 3a of the cancelling cam body 3 and the ball 11 is engaged with the cam recess 10b.
Next, when the knob 16 is operated in the direction of an arrow mark B on FIG. 1, about the shaft portions 13a and 13b of the knob holder 13, then the knob holder 13 is also rotated in the same direction as the knob 16 and the contact holder 21 is slided so that the turn-signal switch 20 is put in a switched situation of "R" shown in FIG. 1 and the turn-signal lamps on the right side of the vehicle are blinked. In addition, when the bracket 5 is rotated in the direction of an arrow mark R, about the shaft portion 5a together with the rotation of the knob holder 13, the nail portion 7 of the ratchet 6 is moved within the rotation locus of the cam projections 3a of the cancelling cam body 3 so that the ball 11 is caused to engage with the cam recess 10a and the bracket 5 is maintained in its rotated position.
At this condition the steering wheel S3 is rotated in the direction of an arrow mark r, i.e. an anti-cancelling direction, whereby the vehicle is turned to the right. By the rotation of the steering wheel S3 the cam projection 3a is caused to abut on the nail portion 7 of the ratchet 6 so as to give a rotation force in the arrow mark R direction to the bracket 5 through the ratchet 6. However, since an additional rotation of the bracket 5 in the arrow mark R direction is prevented by the stopper, not shown, provided on the base plate 1, the ratchet 6 is rotated against the compression coil spring 9 in the direction of an arrow mark C on FIG. 1, about the shaft portion 6a so that the nail portion 7 moves over the cam projection 3a. Accordingly, the bracket 5 is kept in the position rotated in the arrow mark R direction. When the nail portion 7 is separated from the cam projection 3a, the ratchet 6 is rotatably returned in the direction reverse to the arrow mark C direction by the spring force of the compression coil spring 9, and the ratchet 6 is stopped moving when the ratchet 6 is moved to its neutral position against the bracket 5. The ratchet 6 moved to the neutral position is stopped in the neutral position only by the resistance force of the compression coil spring 9 and, therefore, the ratchet 6 does not strike with the bracket 5 so as not to cause loud striking noises. Moreover, even if the ratchet 6 is rotated unnecessarily in the direction reverse to the arrow mark C to exceed the neutral position, the rotation of the ratchet 6 is restricted due to the rotation force in the arrow mark C direction by the compression coil spring 9 and thereby the ratchet 6 is rotated from its over-rotated position back to the neutral position. Next, when the steering wheel S3 is rotated in the direction of an arrow mark l, i.e. the cancelling direction, the cam projection 3a of the cancelling cam body 3 is caused to abut on the nail portion 7 of the ratchet 6. At this time the spring force of the compression coil spring 9 is greater than the force by which the ball 11 is kept in the recess 10a and, therefore, the rotation force of the cancelling cam body 3 is transmitted to the bracket 5 through ratchet 6 whereby the bracket 5 is rotated in the direction of an arrow mark L to be returned back to the neutral position shown on FIGS. 1 and 2. The knob holder 13 and the contact holder 21 are also returned back to the neutral positions in response to the rotation of the bracket 5. Thus, the self-cancelling mechanism is worked.
On the other hand, when the knob 16 is operated from its neutral position in the direction reverse to an arrow mark B, centering the shaft portions 13a, 13b of the knob holder 13, the knob holder 13 is rotated in the same direction as the knob 16 and the contact holder 21 is slided so that the turn-signal switch 20 is put in a switched situation of "L" shown on FIG. 1 and the turn-signal lamps on the left side of the vehicle are blinked. In response to the rotation of the knob holder 13 the bracket 5 is rotated in the direction of an arrow mark L so that the nail portion 8 of the ratchet 6 is moved within the rotation locus of the cam projection 3a of the cancelling cam body 3 and the ball 11 is caused to engage with the recess 10c. When the steering wheel S3 is rotated in the direction of the arrow mark l, the ratchet 6 is rotated in the direction reverse to the arrow mark C so that the nail portion 8 moves over the cam projection 3a. Accordingly, when the steering wheel S3 is rotated in the direction of the arrow mark r, the self-cancelling mechanism is worked in the same manner as set forth above.
In addition, when the knob 16 is rotated from its neutral position shown on FIG. 2 in the direction of an arrow mark D about the pin 15, the operation button 18 of the dimmer and passing switch 17 is pushed-in by the operation portion 16a whereby the dimmer and passing action is carried out, and when the knob 16 is released the knob 16 is automatically returned back to its original position together with the operation button 18 owing to the spring force of the return spring 19.
As set forth above, according to the above embodiment, when the steering wheel S3 is rotated in the anti-cancelling direction with the bracket 5 rotated right or left to move the nail portion 7 or 8 of the ratchet 6 over the cam projection 3a so as to return the ratchet 6 back to the original neutral position, the ratchet 6 is stopped in the neutral position while being braked by the spring force of the compression coil spring 9. Accordingly, the ratchet 6 does not strike against the bracket 5 and, therefore, any striking noise does not occur, which is different from the conventional devices.
FIGS. 4 to 7 show the second to fifth embodiments according to the present invention which are described below only regarding the portions different from the first embodiment described above.
In FIG. 4 the ratchet 6 is made of a synthetic resin and is integrally formed projectively with elastic arm portion 23, as being a spring member, instead of the compression coil spring 9. The elastic arm portion 23 is inserted into a recess 5j formed on the bracket 5 and is caused to function in the same manner as the compression coil spring 9 mentioned above.
In the second embodiment, therefore, when the ratchet 6 is suddenly released after rotated right or left, the elastic arm member 23 can return the ratchet 6 back to the neutral position without causing the ratchet 6 to abut on the bracket 5.
Next, in the third embodiment shown in FIG. 5 the bracket 5 is integrally formed projectively with an elastic arm portion 24, as being a spring member, instead of the compression coil spring 9. The elastic arm portion 24 is inserted into a recess 6c formed on the ratchet 6 and is caused to function in the same manner as the compression coil spring 9 stated above.
The fourth embodiment shown in FIG. 6 is intended for a combination of the second and third embodiments above-stated in which the elastic arm portion 24 projected from the bracket 5 is inserted into the recess 6c of the ratchet 6 and the elastic arm portion 23 projected from the ratchet 6 is inserted into the recess 5j of the bracket 5. As a result, the load acting on the elastic arm portions 23, 24 is dispersed so that the durations of the elastic arm portions 23, 24 can be improved.
In the fifth embodiment shown in FIG. 7 the ratchet 6 and the bracket 5 are provided projectively with the respective pins 25 and 26 which are bridged by a tension coil spring 27 in which the tension coil spring 27 is caused to function in the same manner as the compression coil spring 9.
As set forth above, the second through fifth embodiments shown in FIGS. 4 through 7 have the substantially same functions and effects as the first embodiment shown in FIGS. 1 through 3. | A self-cancelling mechanism is mounted on a steering column of a vehicle, is used for a turn-signal device signalling a change of a running direction of the vehicle and switches off turn-signal lamps by a returning rotation of a steering wheel. A ratchet is pivotally supported to a bracket pivoted to the steering column and is operated by a driver, and a cancelling cam body is arranged between the ratchet and the steering shaft. The ratchet is rotatable from its neutral position against the bracket up to a pair of rotation positions and is forced to the neutral position by an elastic member so that, even if the ratchet is suddenly returned back to the neutral position by the rotation of the steeling shaft in an anticancelling direction, striking noise does not occur. | 1 |
BACKGROUND AND SUMMARY OF THE PRESENT INVENTION
The invention disclosed herein pertains generally to an apparatus and method for cooling the hot gas casings of combustion chambers and more particularly, the hot gas casings of the combustion chambers of gas turbine power plants.
A gas turbine power plant typically includes a gas turbine, an air compressor, and a combustion chamber. The combustion chamber usually includes a combustion space enclosed by a hot gas casing. The gas turbine, the compressor, and the combustion chamber are usually enclosed in a housing. In operation, the gas turbine is supplied with hot gases flowing from the combustion chamber. In the case of prior art gas turbine power plants compressed air supplied by the compressor flows into the combustion chamber through a space located intermediate the hot gas casing and the power plant housing. Because this compressed air has a lower temperature than the surface of the hot gas casing, the air absorbs heat during its transit through the intermediate space. In this fashion, the hot gas casings of prior art gas turbine power plants are cooled by the compressed air supplied by an air compressor. This is disclosed, for example, in Swiss Pat. No. 284 190.
The method and apparatus used to cool the hot gas casings of prior art gas turbine power plants leads to a nonuniform flow of cooling compressed air over these casings. This nonuniform flow produces quite nonuniform casing wall temperatures which leads to thermal wall stresses, particularly when the turbine inlet temperatures are relatively high. Such thermal stresses can lead to cracks in hot gas casings. These thermal stresses and cracks are particularly evident in the hot gas casings of gas turbine power plants having one or more combustion chambers which are external to the power plant housing.
Accordingly, it is an object of the present invention to cool the hot gas casings of the combustion chambers of gas turbine power plants more uniformly in order to avoid the thermal stresses and cracks produced by nonuniform cooling.
A further object of the present invention is to be able to regulate the cooling of the hot gas casings according to the requirements of the situation.
Apparatus for uniformly cooling the hot gas casing of the combustion chamber of a gas turbine power plant, according to the present invention, includes an outer shell which encircles the hot gas casing to form a cooling air channel between the casing and the shell. This outer shell includes air inlet openings to permit cooling air from an air compressor to enter the cooling air channel. The cooling air channel terminates at a combustion air inlet of the hot gas casing.
Compressed air from the air compressor impinges like a jet on the hot gas casing to produce intense cooling. By appropriately adjusting the air inlet openings in the outer shell, as well as the distance of the outer shell from the hot gas casing, the cooling effect can be regulated according to the requirements of the situation. The cooling air is ultimately delivered to a combustion space of the combustion chamber either by being mixed with a primary air source flowing into the combustion space through a primary combustion air inlet, or by flowing into the combustion space through secondary air inlet nozzles.
A preferred embodiment of the present invention employs an optimum number of cooling air inlet openings in the outer shell, i.e., a number determined by the actual turbine inlet temperature prevailing on the inside surface of the hot gas casing.
A further preferred embodiment of the present invention includes the use of air ducts in the cooling air inlet openings. The use of such air ducts results in a uniform distribution of cooling air over the surface of the hot gas casing. The use of such ducts also reduces the possibility that the cooling air stream will be deflected by air flowing off the surface of the hot gas casing, and provides for a physical separation of the cooling air supply from the flow off.
Yet another preferred embodiment of the present invention includes the use of baffles in the cooling air channel for conducting the cool air between the outer shell and the hot gas casing. The use of baffles produces not only local baffle cooling but also film cooling because the cooling air is forced into intimate contact with the outside surface of the hot gas casing as it flows from baffle to baffle.
Yet a further preferred embodiment of the present invention includes the use of secondary air inlet nozzles arranged over the surface of the hot gas casing in order to pass cooling air directly from the cooling air channel into the combustion space. The relatively high pressure of the cooling air injected into the combustion space through the secondary air nozzles permits an increase in the pressure drop across the combustion chamber. In addition the use of the secondary nozzles imparts a relatively high velocity to the cooling air flowing through these nozzles and consequently produces a better mixing of the cooling air with the air entering the combustion space through the primary combustion air inlet.
Yet still another preferred embodiment of the present invention includes a flow restrictor placed between the outer shell and the power plant housing in the path of the air flowing directly from the air compressor to the primary combustion air inlet. In use, such a restrictor produces an increase in the velocity of that portion of the air stream not used for cooling. In addition, such a restrictor acts as an ejector for the cooling air in the cooling air channel, sucking cooling air through the space between the hot gas casing and the outer shell with relatively low flow losses.
Yet still a further preferred embodiment of the present invention includes openings in the hot gas casing through which cooling air may enter so as to produce additional film cooling on the inside walls of the hot gas casing.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of apparatus according to the present invention are described with reference to the accompanying drawings wherein like members bear like reference numerals and wherein:
FIG. 1 is a longitudinal view in cross-section of a gas turbine power plant having a hot gas casing and an outer shell, according to the present invention;
FIG. 2 is an enlarged, cross-sectional view of a cooling air channel encircling a hot gas casing, with air inlet openings in the surface of the outer shell and the hot gas casing;
FIG. 3, a view similar to FIG. 2, shows air inlet ducts in the cooling air inlet openings in the outer shell;
FIG. 4, a view similar to FIG. 1, shows a restrictor placed between the outer shell and the power plant housing;
FIG. 5, a view similar to FIG. 1, shows air inlet ducts in the portion of the cooling air channel near the bottom of the power plant, to produce baffle cooling;
FIG. 5a is an enlarged cross-sectional view of a cooling air channel having baffles arranged between the hot gas casing and the outer shell;
FIG. 6, a view similar to FIG. 1, shows air separators in the air inlet openings in the surface of the outer shell; and
FIG. 7 is an enlarged cross-sectional view of the air separators shown in FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1, a gas turbine power plant according to the present invention includes a power plant housing 1 in which a compressor 3 and a gas turbine 4 are arranged on a common shaft 2. Also contained in the housing 1 is a combustion chamber 5 encircling a combustion space 14. Hot gases are supplied by the combustion chamber 5 to the turbine 4 through a hot gas casing 6 and a turbine inlet 7. An arrow in FIG. 1 shows the direction of the flow of the hot gases from the combustion chamber 5, through the turbine inlet 7, to the gas turbine 4.
Between the compressor 3 and the combustion chamber 5 is an intermediate space 8 bounded on one side by the housing 1. The hot gas casing 6 is enclosed by an outer shell 9 which also bounds the space 8. The space between the hot gas casing 6 and the outer shell 9 serves as a cooling air channel 10 through which air may flow to cool the hot gas casing 6. The outer shell 9 is provided with cooling air inlet openings 11.
When the gas turbine power plant is in operation, compressed air from the compressor 3 flows through an air channel 12 into the intermediate space 8. A portion of this compressed air flows as primary air through a primary combustion air inlet 13 into the combustion space 14 of the combustion chamber 5. The remaining portion of the compressed air serves as cooling air which flows through the cooling air inlet openings 11 into the cooling air channel 10. This cooling air flows over the outer surface of the hot gas casing 6 and in the process absorbs heat from this surface. The cooling air then flows through several combustion chamber secondary air inlets 15 where it is used as secondary air which is mixed with the hot gas in the combustion space 14. The hot gas flows through the turbine inlet 7 to the gas turbine 4, expands as it flows across the turbine, and then flows out of the turbine through an exhaust gas stack 16.
A preferred embodiment of a gas turbine power plant according to the present invention includes a number of small air inlet openings in the hot gas casing 6. With reference to FIG. 2, the part of the hot gas casing 6 which is to be cooled is provided with openings 17 through which the cooling air from the cooling air channel 10 can enter and be mixed directly with the hot gas in the turbine inlet nozzle 7. In this manner, the inner surface of the hot gas casing 6 is exposed to a film cooling.
In order to prevent disturbances to the cooling air flow in channel 10 by air flowing off from the hot gas casing 6, cooling air ducts 18 may be inserted into the cooling air inlet openings 11 of outer shell 9, as shown in FIG. 3. The ducts extend through air inlet openings 11 to a point close to the outer surface of the hot gas casing 6. The presence of these ducts results in a baffle cooling of hot gas casing 6. Furthermore, sufficient space is provided between the individual cool air ducts 18 in order to allow the cooling air to flow off unimpeded after cooling the hot gas casing 6, and without affecting the baffle cooling.
In another preferred embodiment of a gas turbine power plant, according to the present invention, cooling air from the cooling air channel 10 is supplied directly to the combustion space 14 of combustion chamber 5 through the primary combustion air inlet 13 as well as through secondary air inlets. With reference to FIG. 4, the cooling air in air channel 10, after flowing over hot gas casing 6, flows into the combustion space 14 through secondary air inlet nozzles 15 as well as through the primary combustion air inlet 13. In addition a restrictor 19 is provided between the housing 1 and the hot gas casing 6 at the outlet of the cooling air from the cooling air channel 10. The presence of the restrictor 19 causes the air flowing out from the intermediate space 8 to acquire a higher flow velocity than would exist in the absence of the restrictor. In addition, restrictor 19 acts as an ejector for the air flowing into the cooling air channel 10. Thus, the cooling air is more readily exhausted from the cooling air channel 10 which increases the circulation velocity of the cooling air and accordingly improves the cooling effect.
Yet another preferred embodiment of a gas turbine power plant according to the present invention has an improved cooling capability because it employs a mixture of baffle and convection cooling. With reference to FIG. 5a, baffles 20 force most of the cooling air in the cooling air channel 10 to flow over the entire outer surface of the hot gas casing 6 in intimate contact with this surface. With reference to FIG. 5, the lower portions of the hot gas casing 6, where the convective cooling is insufficient, may be provided with additional baffle cooling by providing the cooling air inlet openings 11 both with as well as without cooling air ducts 18.
Still another preferred embodiment of the present invention, in order to achieve a more effective separation of the air flowing into channel 10 from the air flowing out, employs air separators. With reference to FIGS. 6 and 7, these air separators include small cooling air tubes 21 arranged in the outer shell 9. Each of these air tubes 21 leads to an enlarged chamber 22 which is enclosed, and separated from the hot gas casing, by a perforated surface. Thus, the cooling air flows through the small cooling air tubes 21 into the chambers 22. Then the cooling air flows through the openings in the perforated surfaces enclosing these chambers, which surfaces are arranged close to the outer surface of the hot gas casing 6. Since spaces 23 are always provided and arranged between the small cooling air tubes 21 and behind the chambers 22, the cooling air flowing off from the hot gas casing 6 can flow into these intermediate spaces and from there be passed to combustion space 14.
The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification. The invention which is intended to be protected herein, however, is not to be construed as limited to the particular forms disclosed, since these are to be regarded as illustrative rather than restrictive. Variations and changes may be made by those skilled in the art without departing from the spirit of the present invention. | A method and apparatus for cooling the hot gas casing of a gas turbine power plant is disclosed. The apparatus includes a shell which is spaced from but which encompasses the hot gas casing so as to form an air channel about the casing. A compressor provides a supply of cooling air which flows into the air channel through openings in the shell, and which air absorbs heat from the hot gas casing as it flows through the air channel. | 5 |
RELATED APPLICATIONS
[0001] This is a divisional of Ser. No. 12/398,353 filed Mar. 5, 2009 and now U.S. Pat. No. ______. The contents of Ser. No. 12/398,353 are incorporated entirely herein by reference.
BACKGROUND
[0002] The present invention relates to vessels used for high temperature, high pressure microwave-assisted reactions, including but not limited to digestion of materials in robust solvents.
[0003] In general, the term “digestion” refers to the process of analyzing the contents of a material by dissolving that material in a solvent that reduces the compounds that make up the material into their constituent elements or more basic compounds. In such form, the elements or compounds originally present in the material (the “analytes of interest”) can be identified more easily both as to their presence and their amounts. In many cases. however, the analytes of interest comprise only a small portion of the bulk of the material to be digested. As a result, the remaining unanalyzed portion of the material must be removed in order to free the analytes of interest for further analysis.
[0004] As one example, a soil sample can be analyzed for the presence of particular contaminating materials such as heavy metals by heating the sample in a strong acid that breaks down the bulk of the soil material (the matrix) and solvates the heavy metals making them available for further analysis. The resulting solution of elements can be diluted or otherwise prepared and then analyzed for content and quantity, for example using mass spectroscopy, atomic absorption spectroscopy, atomic emission spectroscopy, or other well-understood techniques.
[0005] Some materials will digest in acid at room temperature (i.e., about 20° C.). Other materials will digest when heated to moderate or somewhat elevated temperatures; e.g. 100-150° C. Other materials, however, will resist digestion until the temperature is raised to at least 200° C. and in some cases even higher.
[0006] Additionally, both the nature of digestion and in some cases the composition of the materials being tested result in chemical reactions that generate gases as part of the digestion process. These gases are commonly incidental side products of the breakdown of the matrix of the material. Conversion of the unanalyzed portion of the material to gaseous by-products can be seen as an important part of the digestion process—essentially freeing the analytes for further analysis. The solvents used to effect the digestion process are commonly liquids whose boiling points have a known relationship with temperature and pressure.
[0007] As dictated by the ideal gas law (and the more complex version of the gas laws), a gas that is heated to a higher temperature within the defined volume of such a sealed vessel will exert a correspondingly increased pressure against that vessel.
[0008] In pressurized digestion techniques the temperature of the process is elevated by carrying out the digestion in a sealed heated container. This allows the reaction to reach temperatures above the atmospheric boiling point of the digestion solvent. Increasing the temperature also increases the rate of the chemical reactions which accomplish the digestion. The digestion is thus more complete and faster as temperature is increased.
[0009] In microwave assisted digestion, in which the use of microwaves further accelerates the heating process, a sealed pressure vessel is used to contain the digestion reaction. Because metals tend to shield microwaves or cause sparking in a microwave field, microwave digestion is typically carried out in a microwave transparent vessel formed of an engineering polymer such as polyamide. At the temperatures commonly used for digestion, the pressure in the vessel is generated from two components. Vapor pressure generated by the digestion solvent(s) represents one component, and this component is predictable based upon the temperature of the solvent. The pressure of gaseous by-products generated during the digestion process represents the second component. Thus the amount of pressure in the vessel is related to both the boiling point of the solvent and also to the size and composition of the sample that is to be digested.
[0010] Because samples to be analyzed typically contain unknown amounts of material(s) that may form gaseous by products, the resulting amount of gas pressure is unpredictable.
[0011] Microwave transparent pressure vessels are commonly made from engineered plastics that can withstand relatively high pressures before failing. The nature of polymers and plastics is such, however, that if the vessel fails under pressure, it will tend to fail catastrophically.
[0012] In order to avoid such catastrophic failure, vessels for microwave digestion have been developed that include some means for pressure release. In some cases, the pressure release is provided by a small pathway leading from the interior to the exterior of the vessel with a small portion of the pathway blocked by a diaphragm that will fail at a predetermined pressure. When the pressure in such a vessel exceeds the predetermined limit, the diaphragm will burst and the gases will vent from the vessel without any catastrophic or near-catastrophic failure.
[0013] Commonly assigned U.S. Pat. Nos. 6,258,329; 5,520,886; 5,427,741; 5,369,034 and 5,230,865 are representative of the diaphragm type of pressure release system for vessels used in microwave assisted digestion and related reactions.
[0014] Accordingly, vessels have been developed in which the pressure release is temporary rather than complete and which allow the reaction to continue during and after the pressure release. Such vessels are designed to vent a small amount of gas when the pressure in the vessel exceeds predetermined limit and to re-seal themselves when the pressure drops below the predetermined limit. Examples include commonly assigned U.S. Pat. Nos. 6,927,371; 6,287,526; 6,136,276 and 6,124,582.
[0015] Such vessels commonly operate at 180-200° C. and cannot contain sufficient pressure to allow higher temperatures to be achieved.
[0016] If these vessels are sealed in a manner that attempts to contain gas pressures generated at temperatures above 200° C. (typically by over-tightening threaded fixtures), a higher proportion of these vessels will fail.
[0017] Such failures, of course, reduce efficiency by forcing experiments to be repeated. More importantly, when such vessels are heated above 200° C. and when they release the gases at such temperatures, the release tends to permanently distort the vessel even though catastrophic failure is avoided.
[0018] Because the vessels are formed of sophisticated engineering plastics, they tend to be relatively expensive. As a result, vessel failures result in the economic loss of the vessel in addition to the loss of the particular experiment and the loss of overall efficiency of the testing being carried out.
[0019] Although the capacity to carry out a digestion in sealed pressure-releasing vessels at temperatures up to 200° C. is valuable in many circumstances, there are a number of types of materials that will not digest even at such temperatures and that must be heated significantly above 200° C. before they will digest completely. If a composition fails to digest completely, the likelihood increases that elements will be mis-identified, identified in erroneous quantities, or remain completely unidentified.
[0020] For example, materials such as polymers, lubricating oils, high molecular weight compositions, compositions containing significant proportions of aromatic compounds, and refractory materials all need to be heated higher than 200° C. before they will digest properly. As an example, analyzing plastics in childrens' toy to make sure that it avoids containing undesirable (or in some cases prohibited) amounts of heavy metals or other materials requires such high-temperature digestion. The same is true for many lubricating and related oils which are widely present in a wide variety of industrial machinery as well as automobiles, trucks, trains and airplanes.
[0021] Digestion samples often contain very small amounts of the analytes of interest. The sample size which can be digested in any sealed vessel at a given temperature is thus limited by the safe operating pressure limit of the vessel. Maximizing sample size while maintaining a sufficient temperature for an effective digestion is an important aspect of the technique and increases the accuracy of the analysis
[0022] Therefore, a need exists for vessels suitable for microwave assisted chemistry that can withstand higher temperatures, can contain higher pressure, and can release pressure above a predetermined limit, but while avoiding or minimizing the loss of gases that may contain materials that need to be identified and quantified and while avoiding permanent or catastrophic failure of the vessel.
SUMMARY
[0023] In one aspect the invention is a vessel assembly for high pressure high temperature chemistry. The assembly comprises a cylindrical vessel and a cylindrical vessel seal cover, with the vessel and the seal cover having respective surfaces that, when engaged, define a circumferential interior passage between the vessel and the seal cover. A pressure release opening in the seal cover is in fluid communication with the circumferential passage. A retaining ring surrounds the vessel and the seal cover at the position where the vessel and the seal cover meet for maintaining an outer circumferential engagement between the seal cover and the vessel when pressure forces gases in the vessel to flow into the circumferential passage and then outwardly from the pressure release opening.
[0024] In another aspect, the vessel assembly comprises a cylindrical vessel defining an open mouth at one end with a circumferential lip extending around and transversely from the mouth of the vessel. A seal cover engages and closes the vessel at the mouth. The lip has respective inner and outer circumferential oblique surfaces and the vessel has corresponding respective inner and outer circumferential oblique surfaces that respectively engage the oblique surfaces of the lip.
[0025] A circumferential pressure release channel is defined by the seal cover at the junction of the oblique surfaces of the seal cover and the vessel lip. At least one pressure release opening is in the seal cover in communication with the pressure release channel, and a retaining ring surrounds the seal cover at the position where the oblique surfaces of the vessel and the seal cover meet that radially urges the seal cover against the vessel lip
[0026] In another aspect, the invention is a method of high pressure high temperature chemistry. In this aspect the method includes digesting a sample in a strong acid at a temperature of at least 200° C. in a pressure resistant vessel that includes a lid while exerting a defined force against the lid in order to maintain gases under pressure in the vessel, directing gas under excess pressure from the vessel into a circumferential passage defined by the vessel and its pressure resistant lid, and directing the gas from the circumferential passage outwardly from the lid while preventing gas from flowing outwardly over the edge of the vessel.
[0027] The foregoing and other objects and advantages of the invention and the manner in which the same are accomplished will become clearer based on the followed detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a perspective view of a plurality of vessels according to the invention as typically arranged in a microwave instrument;
[0029] FIG. 2 is an exploded perspective view of one embodiment of a vessel according to the present invention.
[0030] FIG. 3 is an exploded perspective view of a second embodiment of the vessel according to the present invention
[0031] FIG. 4 is a cross-sectional view of the seal cover and probe according to one embodiment of the invention.
[0032] FIG. 5 is in an enlarged cross sectional view of portions of the venting structure according to the invention
[0033] FIG. 6A is a cross-sectional view of the seal cover taken along lines 6 - 6 of FIG. 4 .
[0034] FIG. 6B is a bottom plan view of the seal cover of FIG. 6A .
[0035] FIG. 7 is a top plan view of a second embodiment of the seal cover according to the invention.
[0036] FIG. 8 is a cross-sectional view of a second embodiment of the seal cover taken along lines 8 - 8 of FIG. 7 .
[0037] FIG. 9 is a bottom plan view of the second embodiment of the seal cover illustrated in FIGS. 7 and 8 .
[0038] FIG. 10 is a perspective view of the vessel and seal cover.
DETAILED DESCRIPTION
[0039] It will be understood that although the vessels herein are described in terms of digestion chemistry, digestion chemistry is only one, albeit helpful, example of high pressure high temperature gas-generating chemistry. Thus, the vessels described and claimed herein along with their advantages can certainly be incorporated with other types of high-temperature high-pressure reactions for the same purpose and with the same advantageous results.
[0040] FIG. 1 illustrates a plurality of pressure vessel assemblies each of which is broadly designated at 20 . In an exemplary (although not limiting) arrangement, a plurality of the vessel assemblies 20 are positioned on a turntable 21 or similar platform which in turn is positioned in the cavity of a microwave instrument (not shown). FIG. 1 illustrates twelve such vessel assemblies on the turntable 21 . The nature of the propagation of microwaves in instruments with microwave cavities large enough to hold this plurality of vessel assemblies makes it advantageous to move the vessels within the cavity while the microwaves are being applied. This is most commonly done using rotation in a manner generally analogous to the turntables commonly found in domestic microwave appliances used for cooking
[0041] Each of the vessel assemblies is formed of several parts. In the embodiment illustrated in FIG. 1 , the reaction vessel itself is not visible because it is typically surrounded by a cylindrical sleeve 22 which provides reinforcing support around the vessel. Although the sleeve 22 is optional, it permits the vessel to be formed of a material (typically a polymer) that is highly resistant to chemical attack, while the sleeve, being insulated from the reactants, can be selected on the basis of its strength. Woven fabrics of engineering polymers are useful for the sleeve as are fiber-reinforced polymers and combinations of these materials.
[0042] The vessel and sleeve 22 are positioned within a generally rectangular frame 23 that helps provide a pressure seal during ongoing chemical reactions. The frame is selected primarily for its strength, with cost and ease of manufacture also being considered. Thus, appropriate engineering polymers are typically used for the frame 23 .
[0043] The vessel is closed with a circular seal cover 24 a portion of which is illustrated in the embodiment in FIG. 1 . The lower portion of the seal cover 24 is surrounded by a circular retaining ring 25 , the structure and function of which will be described with respect to the remaining figures.
[0044] A round load disk 26 with a frustoconical side profile is positioned on top of the seal cover 24 within the opening for the vessel defined by the frame 23 . In the illustrated embodiment the load disk 26 operates in conjunction with a pressure screw 27 in the following manner. The pressure screw 27 is threaded and engages within a corresponding threaded opening 30 defined by the frame 23 . When the screw 27 is inserted and turned in the opening 30 , it applies force against the load disk 26 and in turn against the seal cover 24 . Subject to the overall strength of the materials used in the vessel assembly 20 , the amount of pressure exerted by the threaded screw 27 against the load disk 26 and the seal cover 24 will define the pressure load at which gases can escape from the vessel assembly. Thus, in many cases, the user can define the pressure load by tightening the screw to a desired extent.
[0045] FIG. 2 is an exploded perspective view in which a number of the elements are the same as in FIG. 1 . These include the frame 23 , the threaded screw 27 , the vessel sleeve 22 , and the load disk 26 . The vessel 31 is cylindrical and formed of a material (PTFE is exemplary) that is both transparent to microwave radiation and resistant to attack by strong acids (e.g., nitric, sulfuric, hydrochloric) at digestion temperatures. The vessel 31 defines an open mouth 28 at one end.
[0046] FIG. 2 also, however, illustrates the vessel itself at 31 along with its relationship to the sleeve 22 . The seal cover 24 is shown in a more complete view including a probe portion 32 which is hollow and cylindrical ( FIG. 4 ) and into which a temperature measuring device can be inserted to track the temperature of the materials in the vessel during the application of microwave energy.
[0047] FIG. 2 also illustrates the circumferential retaining ring 25 in position around the seal cover 24 as well as one of the pressure release openings 33 that will be described in more detail with respect to FIGS. 4 , 5 and 6 .
[0048] Respective circular openings 34 in the screw 27 , 35 in the load disk 26 , and 36 in the seal cover 24 provide access to the probe during operation of the vessel. Because the probe is sealed, these openings can be open to atmosphere or ambient pressure conditions.
[0049] FIG. 2 also illustrates the lip 37 on the mouth 28 of the vessel 31 which will be described in more detail with respect to other drawings.
[0050] FIG. 3 illustrates a second embodiment of the vessel assembly which in many respects is identical to the embodiment of FIG. 2 , but with an additional fixture that permits pressure monitoring of the reactants inside the vessel 31 . Thus, most of the elements illustrated in FIG. 3 carry the same reference numerals as in FIG. 2 .
[0051] In the embodiment illustrated in FIG. 3 , however, the seal cover 24 is somewhat larger (axially longer) than the one illustrated in FIG. 2 and includes a pressure stem seat illustrated as the threaded opening 40 . In operation a pressure stem 41 is engaged in the seat 40 , typically through a threaded arrangement. The pressure stem 41 can also be formed as an integral part of the seal cover 24 . As will be illustrated and described with respect to FIGS. 4 , 5 and 6 , these items permit the pressure within the vessel 31 to be monitored during the application of microwave energy.
[0052] FIGS. 4 , 5 and 6 are cross-sectional views that illustrate structural and operational details of the present invention. FIG. 4 is a cross-sectional view of the embodiment of the seal cover 24 illustrated in FIG. 3 . In this embodiment, the seal cover 24 includes a head portion 42 from which extends the previously described probe portion 32 . FIG. 4 illustrates the opening 43 defined by the head 42 and the probe 32 into which an appropriate temperature measurement device can be inserted.
[0053] In FIG. 4 only a small portion of the vessel 31 is illustrated and for purposes of describing the operation, the vessel walls are labeled 44 with the lip again designated at 37 . As in the previous drawings, the retaining ring is illustrated at 25 .
[0054] FIGS. 4 and 5 illustrate a pair of pressure release openings 33 in the head portion 42 of the seal cover 24 . These openings are connected to one another within the seal cover 24 by the pressure release passage 45 . Because the release openings 33 allow gas to escape, their illustrated circular cross section is exemplary rather than limiting.
[0055] In the illustrated embodiment, the pressure release passage 45 is defined by an open channel with a semicircular cross section in the seal cover 24 (e.g., FIG. 10 ). When the seal cover 24 engages the vessel 31 , the lip 37 of the vessel forms a bottom wall to the channel to define the passage 45 .
[0056] In normal operation, an inner oblique surface 46 of the seal cover 24 meets a corresponding inner oblique surface 47 on the lip 37 of the vessel 31 . In a similar manner, an outer oblique surface 50 of the seal cover 24 meets and outer oblique surface 51 of the lip 37 . Under normally expected operating pressures, these surfaces will remain engaged with one another and provide the necessary seal.
[0057] At excessive pressures, however, the vessel 31 will tend to disengage from the seal cover 24 enough to break the sealing relationship between the inner oblique surfaces 46 and 47 . This permits gas to reach the pressure release passage 45 and the pressure release openings 33 . Based upon the well understood nature of the behavior of gases, the passageway 45 permits the excess pressure to equilibrate quickly as gas escapes from both of the openings 33 . Two pressure release openings are shown in FIG. 4 , but more could be included (or only one) if desired or necessary.
[0058] FIG. 5 illustrates the specific advantage of the retaining ring 25 . The retaining ring 25 surrounds the seal cover 24 at the position where the oblique surfaces ( 46 , 47 , 50 , 51 ) of the vessel 31 and the seal cover 34 meet. The retaining ring 25 must be strong enough to prevent the outer portions (illustrated at 52 ) of the seal cover 24 from moving outwardly during pressure release. Stated differently, the retaining ring 25 maintains the outer oblique surfaces 50 and 51 against one another so that when gases escape, they escape only through the pressure release passage 45 and the pressure release openings 33 and not through any undesired opening between the outer oblique surfaces 50 and 51 . As illustrated in FIGS. 4 and 5 , the retaining ring 25 covers all of the lower portions of the seal cover 24 and extends beyond the lower portions in a direction towards the vessel 31 and the vessel lip 37 .
[0059] In practice, it has been found appropriate for the retaining ring 25 to have strength on the order of stainless steel and, even in the microwave environment, stainless steel can be used provided it is used in an amount and orientation that prevents arcing or other undesired behavior that metals can exhibit in a microwave field.
[0060] The term “stainless steel” is, of course, applied to a wide variety of alloys that are broadly defined as containing a minimum of 10% chromium (by mass). The tensile strength of stainless steels can vary, depending upon the particular alloy and thus as a baseline, the retaining ring according to the present invention can also be described as having (regardless of its composition) a tensile strength of at least about 500 megapascals (MPa).
[0061] Other materials are, of course, appropriate, provided that they meet the strength requirements.
[0062] It has been found that in the absence of the retaining ring 25 gases will escape between the outer oblique surfaces 50 and 51 frequently resulting in permanent distortion of the vessel rather than a controlled pressure release.
[0063] FIG. 6A is a cross-sectional view of the seal cover 24 taken along lines 6 - 6 of FIG. 4 . FIG. 6 illustrates the retaining ring 25 and the pressure release openings 33 . FIG. 6 also illustrates the pressure stem seat 40 with the pressure measurement passage 54 . As FIGS. 4 and 6 illustrate, the pressure measurement passage 54 extends parallel to the long axis of the seal cover 24 , the probe 32 , and the vessel 31 .
[0064] FIG. 6B illustrates the seal cover 24 in a bottom plan view with the elements carrying reference numerals consistent with the other drawings herein.
[0065] Monitoring the pressure and temperature during the application of microwave energy provides the opportunity to moderate the application of microwave powers while the reaction proceeds. Typically, but not exclusively, the application of microwaves is moderated or halted when the temperature or pressure reaches certain predetermined values. In many cases the capability for such feedback and control can allow the intended reaction to proceed without interruption before pressures reach an amount that must be vented. The use of processors and related electronic circuits to control instruments based on selected measured parameters (e.g. temperature and pressure) is generally well understood in this and related arts. Exemplary (but not limiting) discussions include Dorf, The Electrical Engineering Handbook , Second Ed. (1997) CRC Press LLC
[0066] As FIGS. 4 , 5 and 6 illustrate, the relationship between the seal cover 24 and the retaining ring 25 limits the direction in which the seal cover 24 can move under the influence of pressure from within the vessel 31 . Specifically, because the retaining ring 25 prevents distortion in directions radial to the long axis of the vessel 31 , such excess pressure will tend to force the seal cover to move parallel to the long axis of the vessel to create the previously described openings between the inner oblique surfaces 46 and 47 .
[0067] FIGS. 7 , 8 and 9 illustrate the embodiment of the seal cover 24 without the pressure stem seat 40 , the pressure stem 41 , or the probe 32 . As is generally well understood in the field of microwave assisted chemistry, when a plurality of vessels are exposed to microwave radiation in a cavity, and when the vessels are rotating on a turntable, the contents of each vessel generally experiences the same exposure. Thus, it has been observed that if one vessel is monitored under such circumstances, the observed conditions of that vessel will very likely be the same as all of the other vessels in the cavity at the same time. Thus, as FIG. 1 illustrates, the overall complexity of a plurality of vessel systems can be reduced by limiting the monitoring of temperature and pressure to fewer than all of the vessels. In many cases, monitoring a single vessel provides all of the needed information.
[0068] As a result, many vessels according to the present invention do not need to include all of the details illustrated in FIGS. 4 , 5 and 6 . Thus, FIG. 7 is a top plan view of the seal cover 24 and the retaining ring 25 .
[0069] FIG. 8 is a cross-sectional view taken along lines 8 - 8 of FIG. 7 again illustrating the seal cover 24 and the retaining ring 25 . FIG. 8 also illustrates the pressure release openings 33 , the pressure release passage 45 , and the respective oblique surfaces 46 and 50 on the seal cover that engage the lip (not shown) of the vessel 31 .
[0070] FIG. 9 is a bottom plan view of the seal cover illustrated in FIGS. 7 and 8 . The inner oblique surface 46 thus is illustrated as a concentric circle as is the retaining ring 25 , the outer portions of the vessel 52 and the pressure release passage 45 . FIG. 9 thus best illustrates that the pressure release passage 45 forms, in the illustrated embodiment, a circular passageway around the interior of the seal cover 24 .
[0071] To date, the invention has been used to successfully digest certain materials which have previously been difficult to digest completely based on the pressure and temperature issues described in the background.
[0072] Table 1 represents six tests carried out on approximately 300 mg samples of selenium (Se), arsenic (As) and mercury (Hg) metallo-organic standards obtained from High-Purity Standards (Charleston S.C. 29423, USA).
[0073] The sample and approximately 10 mL of strong acid (concentrated nitric acid) were placed in a vessel according to the invention. Microwaves were applied in a commercially available instrument (MARSTM System from CEM Corporation, Matthews, NC, USA) to raise the temperature above 225° C. Following digestion, the reaction products were filtered, prepared, and identified to give the results set forth in Table 1. The selenium and arsenic were analyzed using inductively coupled plasma optical emission spectroscopy (ICP-OES) and the mercury was analyzed using direct mercury analysis (DMA). Because these samples are metallo-organic compounds, complete digestion is required in order to obtain accurate results. Thus, the accuracy of the results obtained using vessels according to the invention provides evidence that complete digestion was taking place. In Table 1 ppm represents micrograms per gram (μm/g).
[0000]
TABLE 1
Se
As
Hg
0.300 g
ppm
ppm
ppm
#1
47.8
48.7
49.5
#2
50.2
49.7
50.8
#3
51.5
48.6
50.9
#4
51.5
49.2
49.7
#5
53.7
48.9
50.3
#6
54.8
49.4
49.6
AVG
51.6
49.1
50.1
True Value
50
50
50
% Recovery
103%
98%
100%
Std Dev
2.47
0.45
0.63
% RSD
4.78
0.91
1.26
[0074] In other experiments, acetaminophen, Cod liver oil, coal, motor oil, tea leaves, mineral oil, polymers and titanium dioxide were successfully digested at temperatures approaching, and in some cases exceeding 230° C.
[0075] In the drawings and specification there has been set forth a preferred embodiment of the invention, and although specific terms have been employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims. | A method of conducting microwave-assisted high pressure high temperature chemistry is disclosed. The method includes the steps of digesting a sample in a strong acid at a temperature of at least 200° C. in a pressure resistant vessel that includes a lid while exerting a defined force against the lid in order to maintain gases under pressure in the vessel; directing gas under excess pressure from the vessel into a circumferential passage defined by the vessel and its pressure resistant lid; and directing the gas from the circumferential passage outwardly from the lid while preventing gas from flowing outwardly over the edge of the vessel. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 61/800,642, entitled “Low Cost Methods for Harnessing, Controlling, and Efficiently Using Energy”, filed Mar. 15, 2013, which is incorporated herein in its entirety
FIELD
[0002] This invention is related to the field of vehicle operation, interfaces, and instrumentation, and more specifically to improvements in performance and efficiency.
BACKGROUND
[0003] The statements in this section merely provide background information related to the present disclosure, and do not attempt to reflect all prior art or practices in the literature.
[0004] The history of vehicles is largely a history of modifications based on prior versions and consumer/owner/operator preferences. At times, as it is in other fields, development is driven by enthusiasts modifying and experimenting. This requires often appreciable expenditures of capital and labour in a partially wasteful manner; undoing prior work, throwing away parts and consumables, etc. in order to achieve what could in many cases be carried out more expediently and cost effectively by the factory. Accordingly, improved feedback and deal-making is needed at the business and consumer level, to enable reduced waste, a higher standard of living, and a less-polluted environment. As will be seen, the two aspects of this invention do that in a novel and elegant manner.
[0005] The first problem addressed is that of persuading the vehicle producers that it is worth their while not to just engineer the vehicles specifically to function adequately in the hands of a very unskilled operator, ones with no significant understanding of vehicle dynamics or ability to manage the systems if they are allowed to deviate from factory-set conditions chosen for a minimum of performance under all conditions regardless of what the operator does.
[0006] The engineering of the Ford Model T provides an illustrative example. The engine had a severely restricted air intake which lengthened the engine longevity substantially; Without the restriction, horsepower purportedly increased from 22 to 70 hp. As is the general practice today, a minimum longevity came first in engineering. This meant that those wishing a faster vehicle had to be prepared to buy or expend labour on the car and in general, also buy more parts. They could opt to decline from that pursuit, or buy a competitor's car.
[0007] Had Ford offered the car with a restrictor-removing switch which when pressed enabled 70 hp, many model Ts would have had shorter engine lives, eventually affecting sales negatively assuming most people wanted normal engine longevity in a car. Perhaps some customers also had friends or relatives who used the feature unbeknownst to the owner, leaving him or her surprised with a prematurely failed engine. Perhaps in mountainous terrain, using the feature only above 15000 feet altitude, no appreciable extra engine wear would result. However, if left on, perhaps accidentally, at lower altitudes, engine life could be compromised. This is an example of an advanced feature used incorrectly in a products that is sold without such a consumer override interface; a customer can be initially drawn to the feature set or performance figures, then use them incorrectly, and rapidly get themselves into trouble and blame the product. Had the hypothetical restrictor-remover feature been activated through the proposed interface, additional sales could have been expected from enthusiasts seeing that it is easier and cheaper to buy the model T mass-produced with the feature, than to buy a competitor's car and modify it. Further sales would result from people who can suddenly now afford the now-cheaper performance solution they desired.
[0008] A major part of the problem addressed is that energy conservation is most directly in the hands of the operators, with results varying in some cases by more than a factor of 3 in energy consumption by the same vehicle under the same driving conditions. When the vehicle is modified intelligently by those willing to accept any ‘downsides’, emissions can be reduced while the efficiency range increases even more. Some fraction of the lower-performing operators would be interested if they were convinced that the energy cost savings could be for them so high, and are capable of being trained to do so. The results, across millions of drivers, would be significant, and do not require a significant engineering effort or capital investment.
[0009] Improvements in instrumentation are important since they can help operators to recognize where efficiency gains might be made. In fact, one could suggest that drivers are in the best place to effectively utilize instrumentation-driven improvements, because they have the vehicle, a realistic environment, and are willing to drive and in many cases experiment without getting paid beyond energy consumption savings.
[0010] Existing fuel and energy consumption displays produce time lags and other artifacts resulting from use of crude algorithms. These lags are significant enough to demand that an experimenting driver drive at a constant speed over a sustained slope and road surface quality for inconvenient and appreciable time in order to allow the common fuel-time-speed integration gauge to suggest an average energy consumption (e.g. mpg) achieved.
[0011] Traffic and road conditions often change during such a test, hence diluting the test effectiveness. A single other driver in the way, or threatening to be in the way, or a bump in the road sufficient to cause a finely held gas pedal in a vehicle with an automatic transmission to move sufficiently to result in a gear change; Such types of disturbance events will ruin what amounts to a long measurement experiment effort. Minor, seemingly negligible disturbances, can also occur, and without direct and immediate feedback from the efficiency gauge, incorrect conclusions can be reached which result in wasted effort, frustration, and excess energy purchases.
[0012] Hence an interface and feature modification improvement is desired which enhances the familiar energy usage gauge into one which more accurately correlates and reflects the immediate effects of driving technique.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a flow diagram illustrating one embodiment of the decision and processing flow of the proposed User Permission System, one which enables a new mode of operation and makes and begins to propagate and store records associated with the event. It is a generic example process which embodies the proposed operator permission interface, allowing e.g. a driver to at times override battery charge decisions made by a hybrid car management system.
[0014] FIG. 2 is a simplified illustration of prior art algorithms commonly employed in energy efficiency instrumentation in/of numerous existing vehicles.
[0015] FIG. 3 illustrates how some of the improved algorithm aspects can be combined to yield superior display content; content and results noticeably different and more useful than that provided by existing art.
DETAILED DESCRIPTION
[0016] A consumer energy user override interface method is proposed addressing control and/or data management of the vehicle and its instrumentation. Uses a user interface such as a GUI, or tactile feature, such as for example a pushbutton, in conjunction with a controller/processor which logs desired conditions of use for each feature offered, and the timing of the presentation of the offer/feature activation e.g. at a given time relative to the occurrence of the desired conditions, or later (e.g. when safer to perform or after additional data is taken from sensors).
[0017] With the proposed invention, it is possible for the driver to quickly see the fuel or electricity consumption along a given stretch of road in a given gear at a given speed, and at one glance, quickly change speed or gear, and see the difference in efficiency, while under approximately the same wind, road surface, etc. condition, since a change can be effected, and an additional data point taken, within a couple of seconds later; basically on the same stretch of road. One would no longer be restricted to sections of road without changes in elevation, direction, wind-shading trees, etc.
[0018] The purpose is to allow enabled users to temporarily or permanently change an embedded algorithm to suit their custom goals. The system is novel in that it lowers corporate and/or marketing reluctance to include or allow for certain types of features that enhance performance, efficiency, etc. in products marketed and sold to a wide variety of customers, including those untrained or having low technical abilities. An example of this can be taken from the automotive industry, which builds cars for the masses. Careful, technically minded, or risk-taking customers often modify the cars to achieve higher performance, often by performing modifications which can have the side effect of making the average user more likely to have trouble under certain conditions. This can range from the simple, e.g. traction control off, to less restricted intake and outflow pathways for engines. The latter can result in difficult starting. This in turn can be helped by attention to procedures perhaps developed uniquely or on-the-fly, ie. Not worthwhile to build in at stock form in the factory. Another example is in the stock algorithm for transmission shift points or hybrid vehicle decisions regarding when to charge and discharge a battery.
[0019] While it may not be worthwhile to ‘complete the factor version’ of many extra performance modes, and may for sake of avoidance of undesirable feedback (eg. from customers who for lack of understanding or intelligence, may misuse the feature and then complain that the car as a whole is ‘bad’), avoid enabling this type of performance feature even if the vehicle systems could easily support it. It is in these situations that the offering of the proposed interface makes economic sense. See Figure “user permission interface block diagram”.
[0020] The interface provides sufficient control to document (if desired) the users choice to accept responsibility when activating/requesting/accepting the modification event, and provides a programming routine/algorithm to handle any change in displays, operational parameter limits, indicated performance gauges, etc. deemed sufficient to persuade the user not to complain if he or she gets worse resulting performance compared to their expectations, when deviating from ‘stock’ trim. This hopefully results in a net increase in sales which now include customers desiring higher performance that they are willing to manage, while accepting the increased risk of damage or reduced component life. Those customers know that they agreed to documentation when activating key features, perhaps to the point that readers of their future reviews of the vehicle could access the records. The net result should be ‘fair’ reviews or ‘fair’ interpretation of the reviews, actually help sales rather than compromise them. Additionally, the list of features is a natural presentation of forum topics, which, for good vehicles, builds enthusiast demand for sales. See FIG. 1 “Example of Proposed Equipment-User Permission Flow”. The same example, of this family of algorithms, could be used for many different features.
[0021] Proposed Feature Override/Enable User Interface Application Further Embodiment Examples. In one example, a solar system heat storage configuration is proposed; to make a specific choice different that automatically done by the controller; e.g. to make use of tank architecture and features, to overrule the default algorithm designed for average days, in favor of heating less water but to a higher temperature for a particular need before automatic return to normal.
[0022] Another example provides for a combustion engine electric hybrid vehicles, which overrides many cars' built-in algorithm which periodically expends gasoline to charge up the battery. If the customer is going up and down a long hill which takes several minutes, the driver could push a button or otherwise signal the system to deplete the battery as completely as allowable to satisfy battery life and emergency starting conditions, while going uphill. He/she knows that the car will then immediately have an extended downhill section sufficiently long to recharge the batteries. The batteries can be of different types, some energy efficient but not necessarily efficient under high charge or recharge currents, others costing more or being better at both, capacitors, and different engine settings, combined in such a fashion as to provide lowest overall system cost or highest efficiency or performance when requested.
[0023] Another example provides for diesel engine emissions control methods sometimes including a special or ‘purge’ routine which expends fuel in order to assist the catalytic converter. A user driving conservatively while attempting to get high mpg may see his mpg suddenly plummet when the vehicle goes into the purge routine. If the user had known that the drivetrain controller had determined that type of action to be necessary soon, he/she could have selected it to occur at a specific time, e.g. when about to go up a large incline, and ready to gain a little more speed. Such decisions and actions by the user might on occasion remove the need for the purge cycle to run, when it otherwise would have.
[0024] In many cases use, by the operator, of the interface (for example pushing a switch under certain conditions) can be accomplished by a controller which logs the diagnostic readings, choices in efficiency feedback etc, and/or assists marketing by having the ‘proof’ available to show the customer in the event of customer complaints over operational issues caused by their possibly improper use of the override. Can also have interface ask for a form of EULA which reminds/warns them that they are electing to take some risk and possibly to what degree. Can include group or parental controls, etc.
[0025] Improved accuracy and timeliness in indicated fuel consumption allows vehicle operators to see how efficient a gear they are in for the given speed, wind, road surface, terrain, etc. Existing fuel and energy consumption displays produce time lags and other artifacts resulting from use of crude algorithms. These lags are significant enough to demand that an experimenting driver drive at a constant speed over a sustained slope and road surface quality for inconvenient and appreciable time in order to allow the common fuel-time-speed integration gauge to suggest an average energy consumption (e.g. mpg) achieved.
[0026] The proposed invention includes a possible stand-alone enhancement to the familiar energy usage gauge into one which more accurately correlates and reflects the immediate effects of driving technique by using math which achieves the effect of extrapolating the drivable range gained or lost over an interval.
[0027] With this part of the proposed invention, the driver can relatively immediately see the fuel or electricity consumption along a given stretch of road in a given gear at a given speed, at one glance, quickly change speed or gear, and see the difference in efficiency, while under approximately the same wind, road surface, etc. condition, since a change can be effected, and an additional data point taken, within a couple of seconds later; basically on the same stretch of road. One would no longer be restricted to sections of road without changes in elevation, direction, wind-shading trees, etc.
[0028] Existing graphical display techniques could show the new type of trace, store or retrieve the efficiency history, freeing the driver from the distraction task of repeatedly scanning the gauge in order to see the results.
[0029] If it is employed together with the proposed permissions interface the driver would definitely be aware that the computed metric and possibly its display form have been modified so that he or she does not panic and think something is wrong with their vehicle. Since the improved instrument uses sensor feedback and near-immediate extrapolation of the effects, efficiency techniques are more easily identified/discovered as drivers respond to faster and more accurate efficiency feedback, helping them to recognize procedures and responses that save energy (and its cost).
[0030] This can lead to requests for development of further features (e.g. pulse and glide assisting overrides) to join the ‘unlockables’ list. Manufacturers could take advantage of the findings, to engineer changes where most beneficial e.g. to fuel efficiency, safety, or other profit, as well as reaping potential rewards from reporting real-world vehicle energy efficiencies consistently higher (with respect to standardized ratings) than those of their competitors.
[0031] To illustrate an example resulting improvement in an automotive miles per gallon display, imagine that you are driving at 75 mph and have 2 miles of flat ground range left. You are almost empty. If your mpg and range remaining display was of the typical type, it would be suggesting that you have 2 miles of range left based on prior averaging.
[0032] The true figure is affected by your kinetic energy; depending perhaps less on your previously calculated average consumption rate. Consequently, if you hit the brakes, the old gauge would take some time to update new range estimates, which although perhaps moving in the right direction, are still inaccurate, perhaps progressively so.
[0033] If the proposed gauge was available instead, observation of it would indicate firstly that more than 2 miles was available, but then that braking diminished it immediately, since you will not now coast as far. All prior art automotive fuel consumption and range-extrapolation instrumentation do not reflect this as quickly or as accurately, if at all. Nor do they properly handle the additional scenarios below.
[0034] ‘Hitting the gas hard’ uses fuel, but instead of immediately lowering your mpg figure dramatically as typical existing vehicles indicate, the loss in indicated mpg, due to that transient event, should exist due to, and hence be a reflection of, higher drivetrain losses when speeding up the requested amount. Instead, many vehicle gauges indicate a large mpg (miles per gallon) drop; perhaps more than 75%. Typical calculations based only on amount of fuel used per unit distance, or rate of fuel divided by speed, will calculate/extrapolate fuel efficiency and range incorrectly, since the vehicle has not expended that last burst of fuel only to drive the last few seconds at its average speed or the speed over that interval. Much of the energy went into speeding the vehicle up and is now stored in kinetic energy form.
[0035] Many vehicles can actually convert energy more efficiently under increased load under certain conditions. This is a typical performance characteristic of internal combustion engines, which at light throttle opening settings suffer ‘pumping losses’ as the engine pulls against atmospheric pressure. It takes work to pull the intake air through a restriction. This has given rise to the now well known ‘pulse and glide’ technique of higher mpg driving. Any drivers practicing this technique, in a contemporary vehicle with a typical mpg gauge, are being told that the acceleration is extremely inefficient (e.g. 6 mpg) and that coasting while the engine is idling is very efficient (eg 100 mpg); basically the opposite of what is actually going on with the car, while suggesting to the driver, over the short term, that any pulse is bad, and a glide to a near or complete stop is desirable. These incorrect signals actually encourage worse fuel economy. A typical commuting segment involves a start from a stop, and a return to a stop, often a known distance ahead.
[0036] An example of production of the enhanced energy efficiency value, using the proposed method, is shown in FIG. 3 . It is capable of showing the driver the optimum level of acceleration for those segments. One decision involved in the display is the truncation of dramatic energy loss (e.g. ‘-’ve extrapolated mpg when driver brakes hard). The preferred method is simple truncation of the value. It is easy to highlight an area around the zero mark, which in turn provides sufficient information at a glance to many drivers.
[0037] A decision can be made to put a baseline in the display to allow relative comparison to maximum achievable energy efficiency within different constraints eg. ‘engine assumed to be on and in gear while coasting’ or ‘constant speed at the speed limit, with gentle changes when the limit changes’ although other basis/bases could also be incorporated. Range remaining and its rate of change might be the favorite metric or ‘channel’ to display.
[0038] Unlike the case for most if not all present gauges, substantial loss in mpg should be reflected when brakes are applied, or corners are turned that cause extra friction, winds etc. The invention augments the immediate/current fuel consumed/unit distance with acknowledgment of what is going into kinetic energy, which represents converted but still stored energy enabling extra miles of range.
[0039] A further variation allows augmentation by acknowledgment of fuel being consumed to store potential energy, e.g. by extrapolating the range calculation along whatever the sensed slope is, and/or with a map reading/look-up to extrapolate where the car would come to a halt if ideally managed by the driver and traffic conditions. Again, refer to FIG. 3 . Simple calculations can suffice and yield acceptable results. e.g. an electric vehicle's long-term average kWh/mile consumption figure could be used: Assuming it is 240 Wh/mile at the current speed, which converts to 864 kJ/mile, and that the car maintained 60 mph while investing the electrical energy to gain 360 kJ of potential energy over a 30 second interval (equivalent to an elevation gain of 100 m with a 1200 kg vehicle: Potential Energy=mgh=1200 kg*say30 m*10 m/ŝ2), one should expect that an accurate energy consumption gauge would reflect a significant range change only if there were extra losses in drivetrain efficiency; ie in the motor or batteries, due perhaps to higher current draws. The energy consumption gauges typical in prior art would reflect upwards of 120+360=480 kWh consumed, and estimated range might be dropped accordingly.
[0040] Over the long-term, the gauges may generally continue to do a simplistic average ( FIG. 2 ) over several hours and a return trip, and will to some extent average out these peaks, but the driver has had inadequate or incorrect real-time information to help him or her try changes in driving technique or style, to see what positive effect they may have had on fuel economy. They are instead left with thoughts like “Guess it was poor mpg. Maybe I need to go slower uphill; it read heavy consumption back there”, which is an example of a conclusion often incorrect under some conditions. Using the proposed method and displaying the superior real time result, the anticipation is built-in (perhaps to a selectable amount), that one will later recover much of the energy by using less electricity while descending the other side of the hill. This affords the driver a display of how efficiently the vehicle and its drivetrain are actually functioning over the interval just measured; perhaps 1 second ago.
[0041] Examples of slope/grade information include accelerometers, either built into the vehicle, supplied by a cellphone, or other plug-in or wireless device, or by map lookup or GPS integration. If the vehicle senses acceleration changes to an amount not correlating to a change in horizontal speed alone, a slope and corresponding change in potential energy has happened. In one example, the gauge may be configured to use the acceleration, including its vertical component, but its horizontal component can be used if it is deemed a convenient source of speed change information via time integration) and speed, or grade or altitude information, to determine the altitude gained, and multiply it by the mass of the vehicle in order to compute the gain or loss in potential energy (mass*gravity*(height change)), and obtain the gain or loss in kinetic energy by ½*mass*(speed change)̂2. The estimated range remaining may be calculated based on estimations of how far the vehicle in average conditions will coast assuming a return to an original starting elevation and speed. Assumption of zero speed and trip-start elevation and a temporary reset to current speed and elevation is the preferred embodiment.
[0042] The accuracy and timeliness of the improvement in indicated fuel consumption then allows vehicle operators to see how efficient a gear they are in for the given speed, wind, road surface, terrain, etc. Prior art requires the driver to drive at a constant speed over a sustained slope and road surface quality for appreciable time in order to allow the common fuel-time-speed integration gauge to suggest an average e.g. mpg achieved. Traffic and road conditions often to not allow this; a single other driver in the way, or threatening to be in the way, or a bump in the road sufficient to cause a finely held gas pedal in a vehicle with an automatic transmission to move sufficiently to result in a gear change; either event will ruin what amounts to a long measurement experiment. With the proposed invention, the driver can relatively immediately see the fuel or electricity consumption along a given stretch of road in a given gear at a given speed, at one glance, quickly change speed or gear, and see the difference in efficiency, while under approximately the same wind, road surface, etc. condition, since it is only seconds in time later on the same stretch of road.
[0043] A few examples to further illustrate the usefulness of the invention: When using/requesting both potential and kinetic energy augmentation in the primary consumption level display (e.g. be it a number, graph, etc. as has been the practice in general for data displays), lower than normal fuel efficiency indications are a now more reliable, immediate, and valuable diagnostic for the vehicle operator: Perhaps wheel misalignment occurred after a bump. It can then be caught at an early enough stage to prevent expensive tire wear or accidents at higher speed. It could be an early warning of low tire inflation pressure, possibly signifying a puncture. Perhaps something has come loose on a roof rack and now causes more drag and is in danger of falling off and causing a hazard. Perhaps the fuel obtained at the last fillup is of lower quality or energy content.
[0044] Existing methods of supplying grade information include accelerometers, either built into the vehicle, supplied by a cellphone, by map lookup or GPS integration.
[0045] Formulae may be added to the algorithm in different ways. The method shown in FIG. 3 applies a form of integration over terrain given an assumed vehicle speed profile. One could alternatively add the effect in earlier if that is more easily implemented with the tools on hand, or judged to result in a nicer display.
[0046] When more accurate results are desired (e.g. ‘calibration’), the simulation may be tuned by adjusting its setting to mimic actual results obtained by data collection over time. Those trained in the art can include math to progressively ‘learn’ the vehicle's characteristics over time and different conditions, given the sensors and the overall proposed invented algorithm aspects, resulting in ever more accurate instrumentation and vehicle diagnostic capabilities.
[0047] FIG. 3 used simplified expressions for estimating energies and extrapolating range, but there are far more accurate mathematical solutions that can be employed for the purpose. Taking road surface readings from a map or estimating them through calculations quantizing drag components, and with deceleration measured, logged, and updated as the vehicle travels different roads, and has its relationship with speed established; e.g. usually higher speeds result in higher deceleration rates due to nonlinear wind resistance.
[0048] FIG. 3 and these examples illustrate to engineers or programmers how and where to insert their math of choice in order to customize the proposed invention. Those skilled in the art will understand that a system may be configured in different ways given particular parameters desired.
[0049] The kinetic energy to miles extrapolation may be as simple as a look-up table containing coasting distance versus speed if one has been developed or tuned for the vehicle, perhaps based on previous measurements. In another example, a constant, average or piecewise deceleration can be assumed and used in: potential coasting distance=initial_speed*t−½*deceleration*t̂2. Where t is the interval of time. An example result would be ‘12 mph gained; enough to go an extra 80 meters to a halt]’, or ‘12 mph gained; enough to coast 130 m until I'm back down to the 50 mph I started at.’, which is the preferred embodiment of the rule/assumption that has to be made in order to extrapolate the consumption and miles in a manner meaningful to the driver. The short-term mpg can be thus calculated, and longer term averages and remaining range figures can be updated based on short and prior long term calculations and the amount of fuel or electrical energy reserve remaining.
another embodiment can include using sensors and data storage to parameterize the user's typical commute or other repeated trips. The knowledge thus gained can be used to calculate an average expected mpg for the trip. Since the topography and possibly also other conditions are known, the system can calculate even more precisely when fuel is being wasted or conserved at a rate different than the average or different than at that point on previous trips. This allows a display to provide information that might include today's mpg differences (above or below historical average, accounting for wind and temperature), or messages to highlight significant differences. Any long-term differences that are not accountable by temperature, rain, wind resistance etc. provide diagnostic information about the vehicle drivetrain health; e.g. tire pressure, fuel problem etc. Shorter term or occasional indicated mpg variations, on the other hand, effectively teach the driver how to best drive the route. Prius pulse and glide example—people are currently fighting the existing engine shutdown rpm etc. settings while decreasing the fraction of time they can devote to driving safely. In those cases, the proposed invention makes their efforts easier, likely enables higher efficiency, and increases safety.
[0052] Catch All for Claim Support:
[0053] The invention provides two methods. The first is a method for a user to override configurations and control decisions, by providing a user access to control variables (e.g. switch states), a presentation of a contract and terms which warn them of general and feature-specific associated risks/consequences, subsystems for logging the response, authenticating, and propagating the information to locations where the vendor and other customers can verify the decisions made. The control variables may include states of switches, relays, other actuators, output voltages or currents, or content on displays. A decision to be overridden may involve diesel engine purge cycle timing. Alternatively, a decision to be overridden may involve a hybrid drivetrain battery charging, or may involve a hybrid drivetrain changing the relative allocations of power to and from subsystems/subcomponents. Or, a decision to be overridden involves redirection of energy into smaller capacity fast-charge, fast results storage or larger capacity zones. Alternatively, a decision to be overridden may involve redirection of energy into different energy storage systems with different characteristics. Alternatively, a decision may be made for economic or performance reasons. A decision may be made to alter the method of computing the energy usage for a vehicle. The presentation or user interface may illustrate estimates of the degree of risk involved. The authentication system may offer different levels of access to control. e.g. ‘parental controls’. The information may be propagated to customers, or alternatively, may be propagated to marketing representatives, or may be propagated to locations to support manufacturer assertions of blame in the event of customer dissatisfaction.
[0054] The second method provides an enhanced vehicle efficiency measurement for real time display, by using sensors, data, and extrapolation techniques to account for the effects of changes in kinetic and potential energy, terrain, and traffic conditions. The sensors may include, but are not limited to an odometer, a speedometer, devices or techniques for estimating or weighing the vehicle in order to determine its current mass, a global positioning system (GPS), fuel or energy flow devices or techniques, altitude measurement or estimation devices or techniques, moisture sensors to detect road conditions. The sensors may report data on other vehicles, and may share information among vehicles when users request and allow access. Data may include performance data paramaterizing or simulating the performance of energy storage systems (e.g. different batteries) under different conditions, vehicle simulation parameters, vehicle subsystem simulation parameters, terrain map(s), external data accessed remotely and which may change, road conditions, vehicle mass. The extrapolation techniques may include integration over time and distance, include assumptions of constancy in time or distance derivatives of parameter or variables, over an interval, linear interpolation, piecewise integration, assumptions for conditions affecting the result but that are not readily available or convenient to obtain more directly, and other data relevant to a user. Extrapolation techniques may alternatively include different units of measure and conversions, look-up tables, access to remote resources traffic conditions, weather artifacts, reaction to other vehicles, or other known techniques. The extrapolation techniques may also address vehicle or occupant health diagnostics. The display may include any of: numbers, text, graphics, storage, recall, remote connection, or other data viewing formats. The display may additionally display to/contact remote databases or personnel. The display graphics may include but are not limited to any of: filled black and white or colors, motion, blinking, highlighting, strip charts, graphs, or other display graphics known in the art.
[0055] Boiler Plate:
[0056] It will be readily understood that the components of the present invention, as generally described and illustrated in the Figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the invention, as represented in the Figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of certain examples of presently contemplated embodiments in accordance with the invention. The presently described embodiments will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout.
[0057] The invention has been developed in response to the present state of the art and, in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available apparatus and methods.
[0058] Embodiments in accordance with the present invention may be embodied as an apparatus, method, or computer program product. Accordingly, the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.), or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “module” or “system.” Furthermore, the present invention may take the form of a computer program product embodied in any tangible medium of expression having computer-usable program code embodied in the medium.
[0059] Any combination of one or more transitory or non-transitory computer-usable or computer-readable media may be utilized. For example, computer-readable medium may include one or more of a portable computer diskette, a hard disk, a random access memory (RAM) device, a read-only memory (ROM) device, an erasable programmable read-only memory (EPROM or Flash memory) device, a portable compact disc read-only memory (CDROM), an optical storage device, and a magnetic storage device. In selected embodiments, a computer-readable medium may comprise any non-transitory medium that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device.
[0060] Computer program code for carrying out operations of the present invention may be written in any combination of one or more programming languages, including an object-oriented programming language such as Java, Smalltalk, C++, or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on a computer system as a stand-alone software package, on a stand-alone hardware unit, partly on a remote computer spaced some distance from the computer, or entirely on a remote computer or server. In the latter scenario, the remote computer may be connected to the computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
[0061] The present invention is described below with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions or code. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0062] These computer program instructions may also be stored in a computer-readable medium that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable medium produce an article of manufacture including instruction means which implement the function/act specified in the flowchart and/or block diagram block or blocks.
[0063] The computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0064] Embodiments can also be implemented in cloud computing environments. In this description and the following claims, “cloud computing” is defined as a model for enabling ubiquitous, convenient, on-demand network access to a shared pool of configurable computing resources (e.g., networks, servers, storage, applications, and services) that can be rapidly provisioned via virtualization and released with minimal management effort or service provider interaction, and then scaled accordingly. A cloud model can be composed of various characteristics (e.g., on-demand self-service, broad network access, resource pooling, rapid elasticity, measured service, etc.), service models (e.g., Software as a Service (“SaaS”), Platform as a Service (“PaaS”), Infrastructure as a Service (“IaaS”), and deployment models (e.g., private cloud, community cloud, public cloud, hybrid cloud, etc.). | Methods and systems are provided for improving vehicle performance and efficiency. The performance is improved by allowing the user to customize parameters and other features through the use of an interface accessible to the vehicle operator or owner, which enables and encourages development and rewards many stakeholders including vehicle producers and third party vendors (e.g. aftermarket), customers, maintenance service providers, and insurance companies. One form of performance improvement, a novel method of accomplishing an enhanced form of energy efficiency calculation for near real-time display to the operator, is provided in detail. | 1 |
BACKGROUND
[0001] This invention relates to trucks and more particularly, to systems that facilitate remote warnings of vehicle conditions of the trucks.
[0002] Typical tractor-type trucks are designed to tow trailers and semi-trailers having large loads that may include goods, supplies or other freight. Vocational trucks are designed to perform particular functions. Vocational trucks may include, for example, garbage trucks, cement mixers, concrete pumpers, etc.
[0003] Trucks with diesel engines could include a diesel particulate filter (DPF) for removing diesel particulate matter or soot from the exhaust gas. The particulate collects or accumulates on the filter.
[0004] The filter can be a disposable filter that can be replaced. The filter can also be cleaned (i.e. a non-disposable filter) by burning off the accumulated particulate matter in a process known as regeneration. Regeneration can be passive or active. Passive regeneration utilizes a catalyst which allows the particulate matter to oxidize at a lower temperature than it would otherwise. Active regeneration uses control of the engine or additional devices to heat the filter to very high temperatures at which the soot could burn off (i.e. combustion). Regeneration can take place when the accumulation of the particulate matter on the filter reaches a pre-determined level.
[0005] Active regeneration typically takes place in an automatic manner. A notification is provided that regeneration is about to take place within a predetermined period of time (in two minutes for example). Regeneration takes place at end of this period of time without operator action.
[0006] An operator, if the truck is so equipped, has the ability to override the automatic regeneration by activating an inhibit switch located within the truck. The operator may activate the inhibit switch for a variety or reasons. For example, the vehicle may be in a tunnel or other closed space such as a garage where it may be unsafe to generate the very high temperatures needed for burning off the soot.
[0007] The notification of regeneration could be in the form of an indication in the instrument panel located in the dashboard of the cab portion of the truck for example. While the notification via instrument panel on the dashboard may be adequate in some situations, it is not optimal or sufficient in other situations. Accordingly, in some embodiments, improved methods of notification are described.
SUMMARY
[0008] In one embodiment, a system for providing external notification of a vehicle event comprises: a reader device connected to a control unit providing status of at least one vehicle condition, the vehicle having a diesel particulate filter (DPF); a plurality of warning devices connected to the reader device; and a power supply connected to the reader device and the warning devices. The reader device receives data via data lines from the control unit, decodes the received data to detect the occurrence of a vehicle event relating to the DPF and controls ground signal lines of the warning devices to trigger at least one of the warning devices based on the detection of a particular type of vehicle event.
[0009] In another embodiment, a method for providing external notification of a vehicle event comprises: receiving data from a control unit; decoding the received data to detect occurrence of a vehicle event corresponding to a diesel particulate filter (DPF) regeneration; and triggering at least one of a plurality of external warning devices based on the detection of a particular type of vehicle event.
[0010] In a further embodiment, a truck with a diesel particulate filter (DPF) comprises: a reader device receiving data corresponding to vehicle conditions; a plurality of warning devices each having a ground signal connected to the reader device; and a power supply connected to the reader device and to each of the warning devices wherein the reader device decodes the received data to determine the occurrence of a vehicle event relating to the DPF and controls the ground signal lines of the warning devices to trigger at least one of the warning devices based on the detection of a particular type of vehicle event.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The several features, objects, and advantages of Applicants' invention will be understood by reading this description in conjunction with the drawings, in which:
[0012] FIG. 1 illustrates a notification circuit in accordance with exemplary embodiments; and
[0013] FIG. 2 illustrates a method in accordance with exemplary embodiments.
DETAILED DESCRIPTION
[0014] The following description of the implementations consistent with the present invention refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. The following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims.
[0015] According to exemplary embodiments, a notification system is disclosed. The exemplary notification system may provide a warning or notification of a vehicle event to an operator of a truck that is outside of the truck. For purposes of this invention, the term “external” may refer to a location outside the truck (e.g. a cab portion). This notification may supplement a notification that may be provided in or by the instrument panel.
[0016] For active regeneration, the engine can be programmed to operate or run in a particular way so as to heat the exhaust to a high temperature of around 600° C. for example. The work required to heat the exhaust is performed by the engine.
[0017] An operator may be notified of the condition of the DPF and action to be taken. The action to be taken may be based on the DPF condition. For example, the operator may be notified that a regeneration is recommended when the soot level reaches a particular level (may refer to this as a first level for example). As the soot level on the DPF increases (may refer to this as a second level for example), the operator may be notified that a regeneration is needed. As the soot level increases further (may refer to this as a third level for example), the operator may be notified that a regeneration is required immediately. If each of these conditions or notifications are ignored and the level increases even further (may refer to this as a fourth level for example), the operator may be notified that the vehicle be stopped immediately for service.
[0018] In exemplary trucks such as those built by Mack® Trucks, the various notifications highlighted above may be referred to by a “level” designation. For example, the condition associated with the DPF as described above may be designated as “Level 1”, “Level 2”, “Level 3” and “Level 4” with Level 4 being more critical than Level 3 which is more critical than Level 2 which is more critical than Level 1.
[0019] The truck may be a cement dumper or a cement mixer for example. In operation, the cement dumper may be delivering cement to a third story of a building for example. At this time, the operator is typically outside the truck. Therefore, the notification provided via the instrument panel is not visible to the operator who is unaware of the need and level of regeneration. If the exhaust has to be heated for regeneration, the engine will reduce power to other functions being performed such as delivering the cement to the third floor and instead provide power for heating the exhaust. As a result, the cement delivery may cease or the cement may not reach the intended destination. This problem may also occur if the truck is operating in closed locations such as an underground garage or a tunnel, etc.
[0020] An exemplary notification circuit such as circuit 100 of FIG. 1 may provide the supplemental notification. Notification circuit 100 may include a power supply 110 , a reader device 120 , a first warning device 130 and a second warning device 140 . The first warning device 130 may be a LED strobe lamp or a flashing lamp or similar visual device providing a visual signal. The second warning device 140 may be a horn or similar auditory device providing a sound. The power supply may be a 12 volt DC power supply. The warning devices may be located on an outside portion of the truck such as at the rear of the truck for example. Each warning device may correspond to a particular type of notification provided.
[0021] Reader device 120 may receive data from the engine electronic control unit (ECU) 105 of the vehicle via data lines 122 and 124 . The engine ECU 105 may broadcast data (such as regeneration data) over a J1939 serial bus that is used in heavy duty trucks for example. The engine ECU provides information on vehicle condition and is known. Among the conditions on which the module provides information are status of the DPF and regeneration for example. The regeneration may be referred to herein as a vehicle event.
[0022] Reader device 120 may decode the data to determine various conditions associated with the vehicle. In exemplary embodiments, these conditions may include, for example, the status of the DPF and a notification of DPF regeneration (or vehicle event).
[0023] Reader device 120 receives power from power supply 110 and is connected to ground 125 . Both the first and second warning devices 130 and 140 also receive power from power supply 110 . The ground signals 126 and 128 of respective warning devices 130 and 140 may be controlled by reader device 120 to provide the corresponding notification.
[0024] If reader device 120 detects a particular notification or vehicle event, ground signal 126 of first warning device 130 may be controlled by the reader device to trigger the first warning device.
[0025] If reader device 120 detects another notification that is more critical, ground signal 128 of second warning device 140 may be controlled by the reader device to trigger the second warning device.
[0026] For the more critical notification, in exemplary embodiments, ground signal 126 of first warning device 130 may also be controlled simultaneously by the reader device to trigger the first warning device 130 (i.e. in addition to triggering the second warning device 140 for example). This may provide multiple simultaneous warnings.
[0027] A method in accordance with exemplary embodiments may be described with reference to FIG. 2 . An engine electronic control unit (ECU) may broadcast information on vehicle conditions over a J1939 serial bus, for example, at 210 . A reader device may receive data over data lines and decode the received data at 220 . The reader device may determine if a vehicle event corresponding to the DPF regeneration is detected at 230 . If the DPF regeneration event is detected, a determination may be made as to the urgency level of the regeneration at 240 and 250 respectively.
[0028] Purely for illustrative purposes, using the exemplary designation of Mack trucks as described, a determination may be made as to whether the type of regeneration is a Level 2 or a Level 3 regeneration. If a Level 2 regeneration event is detected at 240 , a first warning device may be triggered at 245 . If a Level 3 regeneration event is detected at 250 , a second warning device may be triggered at 255 . In alternative embodiments, both first and second warning devices may be triggered at 260 with detection of a Level 3 regeneration.
[0029] It will be appreciated that the procedures (arrangement) described above may be carried out repetitively as necessary to perform vehicle maintenance. To facilitate understanding, many aspects of the invention are described in terms of sequences of actions. It will be recognized that the various actions could be performed by a combination of specialized circuits and mechanical elements.
[0030] The invention is not limited to implementation in vocational vehicles; it could be implemented in any vehicle utilizing a diesel particulate filter (DPF) with active regeneration. In addition, the invention is not limited to utilizing a J1939 serial bus for communicating data to the reader device. Other protocols for communicating vehicle data may be substituted for the J1939 protocol. The number and types of regeneration that can be detected/initiated may vary. The number and types of warning devices that could be used may also vary. In the exemplary embodiments described above, a warning device for each of the four levels may be included.
[0031] Thus, the invention may be embodied in many different forms, not all of which are described above, and all such forms are contemplated to be within the scope of the invention. It is emphasized that the terms “comprises” and “comprising”, when used in this application, specify the presence of stated features, steps, or components and do not preclude the presence or addition of one or more other features, steps, components, or groups thereof.
[0032] The particular embodiments described above are merely illustrative and should not be considered restrictive in any way. The scope of the invention is determined by the following claims, and all variations and equivalents that fall within the range of the claims are intended to be embraced therein. | A system for providing external notification of a vehicle event to an operator includes a reader device connected to a control unit providing status of at least one vehicle condition with the vehicle having a diesel particulate filter (DPF), a plurality of warning devices connected to the reader device and a power supply connected to the reader device and to the warning devices wherein the reader device receives data via data lines from the control unit, decodes the received data to determine the occurrence of a vehicle event relating to the DPF and controls ground signal lines of the warning devices to trigger at least one of the warning devices based on the detection of a particular event. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a U.S. national stage application under 35 U.S.C. §371 of International Application No. PCT/DE2015/100391, filed on Sep. 14, 2015, and claims benefit to German Patent Application No. DE 10 2014 113 676.4, filed on Sep. 22, 2014. The International Application was published in German on Dec. 10, 2015, as WO 2015/185041 A2 under PCT Article 21(2).
FIELD
[0002] The invention relates to an underwater sound damper for reducing waterborne sound.
BACKGROUND
[0003] When carrying out work underwater, in particular when inserting an object into the underwater floor, the resultant sound is radiated from the object into the water surrounding it. Underwater sound dampers are known for reducing underwater sound, also referred to as waterborne sound, i.e. the sound in the water.
[0004] Underwater floors are understood to mean the fixed floor body below a water column. An underwater floor in the context of the present invention is a seafloor or the bed of a dock or inland water such as a lake or river. The objects that are usually inserted into the underwater floor when carrying out work underwater are foundation bodies such as piles or construction parts such as wall elements, which are inserted by means of drilling or driving into the underwater floor. Within the context of the invention, other sound-emitting devices such as a drilling pipe can also be understood as objects to be inserted into the underwater floor.
[0005] When drilling, vibrational driving or pulsed driving, considerable sound emissions are emitted from the object inserted into the underwater floor, but also from the underwater floor, into the surrounding water. The sound is produced at the friction surface between the object and the underwater floor and is transmitted therefrom into the surrounding water.
[0006] Underwater sound, as is produced when working underwater as described above, can be perceived by marine mammals, such as porpoises and seals, over large distances. Any animal that uses its hearing for communication, orientation and for foraging is in particular adversely affected by underwater sound. Permanent hearing damage can thus result in death in these animals.
[0007] Various techniques are known for reducing the sound. In a bubble curtain, compressed air tubes are laid around the edge of the underwater construction site. These are connected to compressors and pump compressed air into the tubes on the underwater floor. This compressed air rises in the form of a curtain of air bubbles and thus forms a physical-acoustic, sound-absorbing barrier.
[0008] Instead of the volatile air bubbles that are difficult to control, enveloping bodies made of resilient material can also be used as sound-reducing elements. In this case, a multiplicity of sound-reducing elements are arranged on a support structure. This is a net, for example, which can be flexibly stretched around the sound source in the water. The nets are held in place on the underwater floor by means of weights. The sound-reducing elements and the support structure are referred to as a whole as an underwater sound damper. An underwater sound damper also has a damping effect and can be adapted precisely to the expected sound spectrum. An underwater sound damper is less susceptible to sea currents and is optimally effective over the entire relevant frequency range. Furthermore, in an underwater sound damper, a continuous supply of compressed air like that needed for bubble curtains is not required.
[0009] DE 10 2008 017 418 A1 discloses an underwater sound damper for reducing underwater sound. This consists of a multiplicity of damping elements for reducing underwater sound, which are spaced apart from one another and are distributed over a support structure, for example a net. The support structure is arranged around a sound source at the operation site. A sound source is, for example, a pile that is inserted into the underwater floor by means of driving or drilling.
[0010] The generic document, DE 10 2004 043 128 A1, relates to a pile guiding apparatus for guiding a pile to be driven into the bed of a body of water, which pile is surrounded by an inner and an outer textile curtain, so that the bubbles leaving a nozzle arrangement rise between the two textile curtains. For this purpose, discharge openings are located in the radial direction between the inner textile curtain and the outer textile curtain. Since the bubbles leaving the exhaust openings and rising cannot pass either of the two textile curtains, they remain concentrated in the tube-shaped space between the two textile curtains until they reach the water surface. The nozzle arrangement consists of two rigid legs, which are connected to two joints, and therefore the nozzle arrangement can be opened in order to introduce the pile laterally into the nozzle arrangement. The movable legs are then closed so that the pile is surrounded and fixed in its correct position.
[0011] DE 10 2012 206 907 A1 discloses an apparatus for reducing the propagation of sound, vibrations and pressure surges in a liquid when inserting an object into a substrate having a plurality of damping bodies that can be filled with a gas and a support, on which the damping bodies can be arranged in a suitable position relative to one another. The support comprises a frame having vertical and horizontal pipe elements that are arranged perpendicularly to one another, which frame is movable between a closed position and an open position by means of joints. Alternatively, the frame regions made up of horizontal pipe elements can be coupled to one another by means of cables in order to allow for particularly space-saving storage or space-saving transport of the apparatus when not in use.
[0012] WO 2013/102459 A2 describes a method and an apparatus for handling an underwater sound damper in the region of an offshore construction site, in particular for a pile to be inserted into the underwater floor. The apparatus disclosed comprises a retaining device on which a first end of the underwater sound damper is retained, and a second end of the underwater sound damper that is remote from the first end of the underwater sound damper and can be positioned so as to be movable relative to the retaining device, in particular moved away from the retaining device.
[0013] Furthermore, DE 10 2006 008 095 A1 relates to shell-shaped segments made of a sound-absorbing material, which are connected by hinges and which together form a rigid sound-insulation sleeve.
[0014] GB 2509208 A also relates to a rigid sound-insulation envelope of this type.
SUMMARY
[0015] An aspect of the invention provides an underwater sound damper for reducing waterborne sound when inserting an object into an underwater floor, the underwater sound damper comprising: an upper end; a lower end, opposite the upper end; side edges extending between the upper end and the lower end; a support structure; and sound-reducing elements, wherein the underwater sound damper is separable along the side edges and movable between a closed position and an open position, wherein the support structure includes a lower end, which is fixed so as to be movable relative to at least one floor element, wherein the sound-reducing elements are fastened to the support structure and are spaced apart from one another, and wherein the support structure is formed by a row of a plurality of parallel, vertical cables and/or net strips and/or netting tubes including the sound-reducing elements, and/or wherein the support structure is formed of a net.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The present invention will be described in even greater detail below based on the exemplary figures. The invention is not limited to the exemplary embodiments. All features described and/or illustrated herein can be used alone or combined in different combinations in embodiments of the invention. The features and advantages of various embodiments of the present invention will become apparent by reading the following detailed description with reference to the attached drawings which illustrate the following:
[0017] FIG. 1 a schematic sectional view of an underwater sound damper in a working position;
[0018] FIG. 2 a schematic sectional view of the underwater sound damper shown in FIG. 1 in an intermediate position;
[0019] FIG. 3 a schematic sectional view of the underwater sound damper shown in FIG. 1 in an idle position;
[0020] FIG. 4 a schematic view of an underwater sound damper in a closed position, comprising two retaining elements and two floor elements in an intermediate position;
[0021] FIG. 5 a schematic view of the underwater sound damper shown in FIG. 4 in an open position;
[0022] FIG. 6 a schematic view of an underwater sound damper in a closed position, comprising two retaining elements and one floor element in a working position and comprising an expanded support structure;
[0023] FIG. 7 a schematic view of the underwater sound damper shown in FIG. 6 in an open position;
[0024] FIG. 8 a schematic view of the underwater sound damper shown in FIG. 6 in a closed position, comprising a support structure that is pulled together;
[0025] FIG. 9 a schematic view of the underwater sound damper shown in FIG. 6 in an open position, comprising a support structure that is pulled together;
[0026] FIG. 10 a schematic plan view of an underwater sound damper;
[0027] FIG. 11 a schematic plan view of an underwater sound damper;
[0028] FIG. 12 a schematic plan view of an underwater sound damper;
[0029] FIG. 13 a schematic plan view of an underwater sound damper;
[0030] FIG. 14 a schematic plan view of an underwater sound damper in an open position;
[0031] FIG. 15 a schematic plan view of the underwater sound damper shown in FIG. 14 ;
[0032] FIG. 16 a schematic plan view of the underwater sound damper shown in FIG. 14 in a closed position;
[0033] FIG. 17 a schematic plan view of an underwater sound damper in an open position;
[0034] FIG. 18 a schematic plan view of the underwater sound damper shown in FIG. 17 ;
[0035] FIG. 19 a schematic plan view of the underwater sound damper shown in FIG. 17 in a closed position;
[0036] FIG. 20 a schematic plan view of an underwater sound damper in an open position;
[0037] FIG. 21 a schematic plan view of the underwater sound damper shown in FIG. 20 ;
[0038] FIG. 22 a schematic plan view of the underwater sound damper shown in FIG. 20 in a closed position;
[0039] FIG. 23 a schematic plan view of an underwater sound damper in an open position;
[0040] FIG. 24 a schematic plan view of an underwater sound damper in an open position;
[0041] FIG. 25 a schematic sectional view of an underwater sound damper in a working position; and
[0042] FIG. 26 a schematic sectional view of an underwater sound damper in a working position.
DETAILED DESCRIPTION
[0043] An aspect of the invention is to make it possible to simplify both handling of an underwater sound damper in order to reduce the production or propagation of underwater sound, and handling of the object in the region of work being carried out underwater, such as boring or driving an object into the underwater floor, such that the work processes can be carried out quickly, safely and thus ultimately cost-effectively.
[0044] An aspect of the invention also relates to a method for handling an underwater sound damper and/or for positioning an underwater sound damper in the region of a construction site for an object to be inserted into an underwater floor.
[0045] An aspect of the invention relates to an underwater sound damper for reducing waterborne sound, in particular in the region of a construction site when an object is to be inserted into an underwater floor, the underwater sound damper having an upper end and a lower end that is opposite the upper end, side edges extending between the upper end and the lower end, the underwater sound damper being separable along the side edges and being movable between a closed position and an open position, the underwater sound damper comprising at least one support structure, a lower end of the at least one support structure being fixed so as to be movable relative to the at least one floor element.
[0046] According to an aspect of the invention, the underwater sound damper comprises sound-reducing elements that are fastened to the at least one support structure and are spaced apart from one another, the support structure being formed by a row of a plurality of parallel, vertical cables provided with the sound-reducing elements and/or net strips and/or netting tubes and/or being formed of a net. As a result, both the underwater sound damper and the object are easier to handle than in known underwater sound dampers.
[0047] In the underwater sound damper according to an aspect of the invention, the side edges can move relative to one another between two end positions, that is an open position and a closed position. By the side edges moving away from one another, a body extending deep into the water, for example a vertically held pile, can quickly be moved into the region sealed off by the underwater sound damper in a simple manner. In the closed position, the side edges are positioned slightly spaced apart, are touching one another and/or are overlapping one another. In the open position, the side edges are at a large distance that is larger than the cross section of the object. Depending on the embodiment of the underwater sound damper, the side edges that are movable relative to one another are part of a single support structure, for example, and/or of separate support structures, which are formed for example by a row of a plurality of parallel, vertical cables and/or net strips and/or netting tubes that are provided with sound-reducing elements and are retained on a floor element at the lower end and can float freely at the upper end.
[0048] A net is preferably used as the support structure for the sound-reducing elements. Alternatively to a net, it is also possible to use a grating, a cage, in particular a narrow cage, a wire mat, a perforated sheet plate or a rigid wire mesh. A plurality of the rigid support structures formed as surface bodies are movable relative to one another between the idle position and the working position, preferably in a translational and/or rotary manner. In this case, the support structures are preferably arranged relative to one another in graduated planes or in concentric rings. Support structures in the form of cages can also be telescopic or can be arranged on and/or next to one another, for example in stacks.
[0049] It has proven advantageous that the upper end and the lower end of the at least one support structure are movable in a translational manner relative to one another in a vertical direction and/or in a horizontal direction that is approximately perpendicular to the vertical direction. This makes it possible to gather the support structure in order to move the underwater sound damper between the open position and the closed position or for moving the underwater sound damper to another location and to securely store it in a transport housing.
[0050] Furthermore, it is expedient that the underwater sound damper comprises at least one floor element which is assigned to the lower end of the at least one support structure, the lower end being movable relative to the at least one floor element or being fixed to the at least one floor element. The at least one floor element can be moved in a translational manner in a vertical direction relative to the retaining elements so that the at least one support structure can be expanded or gathered together as a result of the vertical movement of the at least one floor element. This is possible by the lower end of the support structure being fastened to the floor element. Furthermore, the vertical movability of the at least one floor element is advantageous since the at least one floor element can thus be raised from the underwater floor when the underwater sound damper is displaced, making it easier to handle the underwater sound damper. In an underwater sound damper in which the lower end is movable relative to the at least one floor element, the floor element comprises an underwater hoist or deflection roller in order to expand the support structure. The at least one floor element is also used as a mass body that acts against the buoyancy of the sound-reducing elements.
[0051] The at least one floor element is movable in the vertical direction between an idle position and a working position, it resting on the underwater floor when in the working position and resting on or being locked to at least one of the retaining elements in the idle position. In order to move said floor element between the working position and the idle position, the retaining elements are connected to the at least one floor element by the support structures and/or by means of cables. The cables can also be formed as bars. The support structures are preferably movably arranged on the cables or bars.
[0052] The at least one floor element and the retaining elements can be formed as containers having closed walls. However, it has proven advantageous for the at least one floor element and the retaining elements to be designed as cages having walls through which a flow can pass in order for a flow to pass through the underwater sound damper.
[0053] The underwater sound damper preferably comprises a plurality of floor elements, at least one floor element being movable in parallel with a horizontal plane together with one of the retaining elements.
[0054] In order to insert a pile into the underwater floor, it has proven useful for the underwater sound damper to comprise a guide device for a pile, for example a gripper, comprising at least one movable arm for gripping the pile, a retaining element being fastened to the at least one movable arm of the guide device. This makes it possible for the underwater sound damper and the guide device to move between the open position and the closed position. Alternatively or in addition, it is possible for at least one retaining element to be fixed to the hull of a vessel or to be connected to a lifting device, for example a crane or pivot arm, that is fastened to the vessel. A vessel or constructor vessel in the context of the invention is a device that floats and/or is set down on the underwater bed or onshore on the water's edge.
[0055] The underwater sound damper can also be completely independent of a constructor vessel or a guide device. It is therefore possible, for example, for the underwater sound damper, at least one retaining element and/or floor element to be connected to the object by means of at least one movable arm.
[0056] In the closed position, the guide device usually surrounds approximately two-thirds of the pile, in any case more than half the circumference thereof. By contrast, the underwater sound damper preferably surrounds the entire pile. In order to be able to quickly switch between the open position and the closed position, the underwater sound damper preferably comprises a plurality of elements, for example retaining elements, in one plane, which are interconnected by means of bearings. An underwater sound damper therefore consists of four quadrant-shaped retaining elements, for example, which are interconnected by three rotational joints.
[0057] Furthermore, it is also possible to provide intermediate elements, which are still floating in the water, in addition to the retaining elements and the floor elements, in particular for use at great depths or in strong currents.
[0058] The bearings for connecting the elements to one another can be designed as pivot bearings or plain bearings for rotary or translational movement. It is possible for the elements of an underwater sound damper to be connected by means of different types of bearings. For example, an underwater sound damper can be provided with four retaining elements, which comprise a sliding mechanism in the form of a bearing between the two middle retaining elements, and in which the outer retaining elements are connected to the middle retaining elements by means of rotational joint. The arrangement of the bearings or the shape and extension of the elements can be either symmetrical or asymmetrical.
[0059] According to the invention, the object is also achieved by a method according to the features of claim 7 . The additional embodiment of the invention can be found in the dependent claims.
[0060] The invention provides a method in which, in order to move the object through the plane of the underwater sound damper, said underwater sound damper is moved into an open position, in which the side edges are moved away from one another and, in order to insert the object into the underwater floor, the underwater sound damper is moved into a closed position, in which the side edges are moved towards one another. This option of vertically dividing and opening the underwater sound damper like a curtain makes it easier to position the object and to transport it through the plane of the underwater sound damper.
[0061] According to another embodiment of the method, an object is first moved into the insertion position by an insertion apparatus. A guide device and at least two retaining elements of the underwater sound damper are then moved out of an open position into a closed position, the object being retained by the guide device such that it cannot move horizontally and being surrounded by the retaining elements. The underwater sound damper is then expanded, a lower end of the underwater sound damper being moved up to the underwater floor or as far as a floor element resting on the underwater floor. The object is then inserted into the underwater floor by means of the insertion apparatus. The underwater sound damper is then pulled together at least in part, the lower end being moved away from the underwater floor. The guide device and the at least two retaining elements are then moved out of the closed position and into the open position, releasing the object. This simplifies handling of the object and the underwater sound damper.
[0062] In an underwater sound damper having a single support structure, in order to reach the closed position the distance between the side edges extending between an upper end and a lower end of the support structure is reduced. In an underwater sound damper comprising at least two support structures, in order to reach the closed position the distance between two side edges of different support structures is reduced.
[0063] The guide device and the retaining device can in principle be moved between the open position and the closed position independently of one another. It has proven particularly useful for the guide device and the at least two retaining elements to be collectively moved, in particular simultaneously, between the open position and the closed position.
[0064] However, embodiments also exist in which it has proven useful for the guide device and the at least two retaining elements to be moved asynchronously, or independently of one another. The individual elements, for example the retaining elements of an underwater sound damper, can also be moved synchronously or independently of one another.
[0065] It is also expedient for the at least one support structure to be completely pulled together before each movement of the at least two retaining elements, in particular the at least one floor element is moved into the idle position.
[0066] When carrying out work underwater, in particular when inserting an object 1 into the underwater floor 2 , the resultant sound is radiated from the object 1 into the water 3 surrounding it. In order to reduce the underwater sound, also referred to as waterborne sound, i.e. the sound in the water 3 , an underwater sound damper 4 is provided, a few embodiments of which are described in more detail in the following. The method according to the invention is also explained by the embodiments of the underwater sound damper 4 shown in the drawings.
[0067] The method is used for handling the underwater sound damper 4 in the region of an off-shore construction site, in particular for an object 1 to be inserted into the underwater floor 2 .
[0068] The underwater sound damper 4 is particularly effective when the sound source, the object 1 in this case, is surrounded by the underwater sound damper 4 to the greatest possible extent. In order to position the object 1 in the underwater sound damper 4 , which consists of a net for example that is formed as a flexible support structure 5 comprising sound-reducing elements 10 fastened thereto, the underwater sound damper 4 is separated along side edges 6 shown in FIGS. 4 to 9 . The side edges 6 extend between an upper end 7 and a lower end 8 of the underwater sound damper 4 and are each embodied by at least one cable 13 .
[0069] FIGS. 1 to 3 show an object 1 inserted into the underwater floor 2 at the end of the insertion process. An insertion tool 9 is still positioned on the object 1 . The underwater sound damper 4 shown schematically in section comprises the above-mentioned flexible support structure 5 , to which a multiplicity of sound-reducing elements 10 are fastened. Furthermore, the underwater sound damper 4 comprises at least two rigid retaining elements 11 , which are connected to the upper end 7 of the at least one support structure 5 , and a guide device 15 for the erected object 1 , which guide device is also referred to as a gripper. The guide device 15 prevents horizontal movement of the object 1 as it is sunk.
[0070] In the embodiment shown in FIGS. 1 to 3 , the retaining elements 11 are arranged on the guide device 15 . In this case, the retaining elements 11 are fixed directly to the guide device 15 as shown, or are attached to the guide device 15 by means of cables. This configuration allows the retaining elements 11 to release to the water surface, which is preferably carried out by hoists arranged on the retaining elements 11 . The at least two retaining elements 11 , together with the arms of the guide device 15 , are moved in a horizontal plane in order to receive an object 1 .
[0071] Furthermore, the underwater sound damper 4 comprises at least one floor element 12 . The at least one floor element 12 is movable relative to the retaining elements 11 . The at least one floor element 12 can be moved between the underwater floor 2 and the retaining elements 11 by means of the cables 13 extending between the at least one floor element 12 and the retaining elements 11 . Hoists 14 are arranged on the at least one floor element 12 and/or on the retaining elements 11 as a drive. The cables 13 can also be used to guide the at least one support structure 5 . In the underwater sound damper 4 according to the invention, it is also possible for a tube to be retained in the floor element 12 in order to generate a bubble curtain and/or to generate or control buoyancy. The bubble curtain and/or the buoyant body and/or the sound-reducing elements ideally have a common compressed air supply, which comprises a common line and/or a common compressor, for example. The lower end 8 of the at least one support structure 5 is connected to the at least one floor element 12 and is expanded with the releasing of the at least one floor element 12 . Alternatively, the lower end 8 of the at least one support structure 5 can be moved relative to the at least one floor element 12 , it being possible for the lower end 8 to be pulled towards the at least one floor element 12 by means of additional cables and hoists (not shown here). The at least one support structure 5 is retrieved merely by the buoyancy of the sound-reducing elements 10 fastened to the at least one support structure 5 .
[0072] FIG. 1 shows the at least one floor element 12 in a working position. In this position, the at least one floor element 12 is set down on the underwater floor 2 . When the underwater sound damper 4 is active, a curtain that reduces the underwater sound extends between the floor element 12 , which is in the working position, and the retaining elements 11 . The curtain is for example a support structure 5 comprising sound-reducing elements 10 fastened thereto, a bubble curtain having freely rising air bubbles or a combination of different devices for reducing waterborne sound. The water surrounding the underwater sound damper 4 can flow through the curtain; however said curtain encloses a delimited volume of water containing the sound source and thus separates said volume from the environment.
[0073] FIG. 2 shows the at least one floor element 12 in an intermediate position. In this position, the at least one floor element 12 is raised from the underwater floor 2 . The distance from the underwater floor 2 is large enough for the underwater sound damper 4 to be moved away from an object 1 inserted into the underwater floor 2 and towards a new insertion location.
[0074] FIG. 3 shows the at least one floor element 12 in an idle position. In this position, the at least one floor element 12 rests against the retaining elements 11 . The retaining elements 11 are optionally locked to the at least one floor element 12 in the idle position. The idle position is particularly suitable when transporting the underwater sound damper 4 , since the at least one support structure 5 is securely stored in a transport housing 16 . In the embodiment shown, the transport housing 16 is formed by the floor element 12 and the retaining element 11 . The underwater sound damper 4 is preferably opened when in the idle position.
[0075] FIGS. 4 to 9 are schematic views of three different methods for handling an underwater sound damper 4 . The drawings show the retaining elements 11 , one or more floor elements 12 and the at least one support structure 5 and the cables 13 that are tensioned between the retaining element 11 and the floor element 12 when using a flexible support structure 5 . Only a cut-out of the at least one support structure 5 is shown. The at least one support structure 5 can, as a single support structure 5 , for example surrounding the object 1 (not shown), spatially extend downwards. The underwater sound damper 4 can also comprise a plurality of support structures 5 , which are formed as a disc-like wall, for example positioned in front of the entrance to a harbor. A plurality of cables 13 are assigned to each retaining element 11 , at least one cable 13 being positioned on each side edge 6 .
[0076] FIGS. 4 and 5 show an underwater sound damper 4 , comprising two retaining elements 11 and two floor elements 12 . In order to be able to transport an object 1 (not shown here) into the working region, the underwater sound damper 4 can be divided along the side edges 6 . In the variant shown, the opening and closing movement takes place while the underwater sound damper 4 is in an intermediate position. In order to open the underwater sound damper 4 , the retaining elements 11 and the floor elements 12 are pivoted or displaced in pairs, so that the distance between the side edges 6 is increased. The movement 17 of the retaining elements 11 as well as the floor elements 12 and the side edges 6 is denoted by a double-headed arrow. In order to close the underwater sound damper 4 , this movement 17 is reversed. FIG. 4 shows the closed position of the underwater sound damper 4 . In this case, the distance between the side edges 6 is minimized. Alternatively, the side edges 6 can also be positioned so as to overlap in the closed position. FIG. 5 shows the open position of the underwater sound damper 4 . In the open position, the distance between the side edges 6 is much larger than in the closed position. As already shown above, the underwater sound damper 4 shown here can consist of a support structure 5 , which is connected to all the retaining elements 11 and the floor elements 12 . However, the underwater sound damper 4 shown here can also consist of two independent support structures 5 , each support structure being connected to a retaining element 11 and a floor element 12 . In order to move 17 the floor elements 12 , said elements are moved from the underwater floor 2 into the intermediate position shown or into an idle position.
[0077] FIGS. 6 and 7 show an underwater sound damper 4 comprising two retaining elements 11 and one floor element 12 . In order to be able to transport an object 1 (not shown here) into the working region, the underwater sound damper 4 can be divided along the side edges 6 . In order to open the underwater sound damper 4 , the retaining elements 11 are pivoted or displaced such that a wedge-shaped opening is formed between the side edges 6 . When switching between the closed position and the open position, the floor element 12 remains in the working position in contact with the underwater floor 2 and is not moved. The support structure 5 is connected to the floor element 12 .
[0078] FIGS. 8 and 9 show a variant of the method described in FIGS. 6 and 7 , wherein, proceeding from the closed position in FIG. 6 , the support structure 5 is first pulled towards the retaining elements 11 and the retaining elements 11 are then moved in accordance with FIG. 7 until the open position is reached.
[0079] FIGS. 10 to 24 are schematic plan views of the movement 17 at least of the retaining elements 11 . The retaining elements 11 , which are movable relative to one another, optionally also the floor elements 12 , are connected, for example, by means of at least one bearing 18 , as shown in FIGS. 10, 11, 13 to 16 and 20 to 24 . The at least one bearing 18 can be formed as a joint, which allows for a rotary movement 17 between the retaining elements 11 . A joint-like bearing 18 of this kind is shown in FIGS. 10, 13, 20 to 22 and 23 . The bearing 18 can also be a guide, which allows for rotary or translational movement 17 between the retaining elements 11 . A guide-like bearing 18 of this kind is shown in FIGS. 11, 17 to 19 and 24 . The retaining elements 11 , which are movable relative to one another, and optionally also the floor elements 12 , can also be independent of one another, as shown in FIGS. 12 and 17 to 19 .
[0080] FIGS. 14 to 22 show the method for positioning the underwater sound damper 4 and the object 1 in an offshore installation site in order to insert a pile into the underwater floor 2 .
[0081] FIGS. 14 to 16 show a first variant of the method. In this first variant, a multi-part underwater sound damper 4 is provided, in which each part comprises a retaining element 11 and a floor element 12 as well as a support structure 5 (not shown), arranged therebetween. In the open position, the two parts of the underwater sound damper 4 comprise a distance ( FIG. 14 ). This distance, in particular between the side edges 6 , allows for simple, problem-free and secure positioning 19 of the object 1 , which is a pile in this case. The two parts of the underwater sound damper 4 are fastened to a vessel 20 . As soon as the object 1 is positioned in its insertion location, one of the parts of the underwater sound damper 4 is moved 17 towards the other part ( FIG. 15 ) until the closed position is reached ( FIG. 16 ). The movement 17 of one part preferably takes place along a guide fastened to the vessel 20 . Provided that the support structure 5 has not yet been extended, the floor element 12 and the lower end 8 of the support structure 5 are now released to the underwater floor 2 . The work emitting sound can then commence. Once the object 1 has been inserted into the underwater floor 2 , the floor element 12 is moved into the intermediate position or into the idle position and the parts of the underwater sound damper 4 are moved away from one another once again until the open position is reached. The vessel 20 can then be moved to a new insertion position and the process can start over again.
[0082] FIGS. 17 to 19 show a second variant of the method. In the second variant, too, an underwater sound damper 4 made up of at least two parts is also provided, in which each part comprises a retaining element 11 and a floor element 12 , as well as a support structure 5 arranged therebetween. In this case, one part of the underwater sound damper 4 is fastened to a vessel 20 , while the other part can move relative to the vessel 20 in a floating manner. When the underwater sound damper 4 is in the open position ( FIG. 17 ), the object 1 is positioned 19 in its insertion location. The floating part of the underwater sound damper 4 is then moved 17 relative to the part fastened to the vessel 20 ( FIG. 18 ). While the object 1 is being inserted into the underwater floor 2 , the underwater sound damper 4 remains in the closed position ( FIG. 19 ).
[0083] FIGS. 20 to 22 show a third variant of the method. In this third variant, an underwater sound damper 4 is provided, in which the two retaining elements 11 are pivotally interconnected. This underwater sound damper 4 preferably also comprises two floor elements 12 , one floor element 12 being assigned to each retaining element 11 . The floor elements 12 are also pivotally interconnected. Alternatively, the underwater sound damper 4 can also comprise a plurality of joint axles, for example consisting of four pairs, each pair comprising one retaining element 11 and one floor element 12 , the four pairs being rotatably interconnected by means of three joint axles. Each pair covers a quadrant in this case, and therefore the closed underwater sound damper 4 engages around the object 1 . The underwater sound damper 4 can be fastened to a vessel 20 and/or to a lifting device and/or to a guide device 15 , can be retained by a crane on the vessel 20 or can be released from the vessel 20 , for example it can move independently in a floating manner. As described above, the object 1 is positioned 19 when the underwater sound damper 4 is in the open position ( FIG. 20 ). The underwater sound damper 4 is then closed by at least one pivot movement 17 of at least one pair comprising a retaining element 11 and a floor element 12 ( FIG. 21 ), until the closed position ( FIG. 22 ) is reached and therefore the underwater sound damper 4 surrounds the object 1 .
[0084] FIGS. 23 and 24 show the method for handling the underwater sound damper 4 and an object 1 in a construction site between two spits 21 . In a construction site between two spits 21 , it is often sufficient to spread out the underwater sound damper between the two spits 21 in order to protect animals from underwater sound. The spits 21 can be two jetties in a harbor region or can form a bay on the coast. In the region of inland waters, the spits 21 are opposite banks of a river or two bank portions of a lake. The support structure 5 is in this case rigid and consists of a grating, for example. The use of a rigid support structure 5 has proven to be advantageous in particular in an underwater sound damper 4 that remains in the same place for a long time, i.e. is never or only seldom displaced. Alternatively to a grating, it is also possible to use cages, in particular narrow cages, wire mats, plastics mats, perforated sheet plates or rigid and/or flexible wire meshes and/or plastics meshes.
[0085] FIG. 23 shows a fourth variant of the method according to the invention. In this fourth variant, a multi-part underwater sound damper 4 is provided, in which each part comprises a support structure 5 , at least two retaining elements 11 and at least two floor elements 12 . The retaining elements 11 and the floor elements 12 of each part are pivotally interconnected. When moving 17 between the open position and the closed position, the associated pairs consisting of a retaining element 11 and a floor element 12 are collectively rotated around a bearing 18 .
[0086] FIG. 24 shows a fifth variant of the method according to the invention. In this fifth variant, a multipart underwater sound damper 4 is provided, in which each part comprises a support structure 5 , a retaining element 11 and a floor element 12 . Two parts of the underwater sound damper 4 are positioned between the spits 21 in the manner of walls. There is a gap between said two parts. The gap can be closed by the at least one additional part. The at least one additional part is moved 17 relative to the two other parts, for example in a translational manner, between the open position and the closed position of the underwater sound damper 4 .
[0087] FIG. 25 shows an underwater sound damper 4 , which is similar to the underwater sound damper 4 shown in FIGS. 1 to 3 . In the underwater sound damper 4 shown in this case, the retaining elements 11 and the floor elements 12 are connected by means of cables 13 , the floor elements 12 being movable relative to the retaining elements 11 by means of hoists 14 arranged on the retaining elements 11 or on the guide device 15 . The floor element 12 is formed as a transport housing 16 , which receives the support structure 5 comprising the sound-reducing elements 10 outside the water 3 . The transport housing 16 is preferably an open-top mesh cage. If the floor element 12 is released into the water 3 , the sound-reducing elements 10 float. Retained on the support structure 5 , which is connected to the floor element 12 by its lower end 8 , the support structure 5 and the sound-reducing elements 10 are pulled as far as to the underwater floor 2 and are therefore expanded over the entire water column. The upper end 7 of the support structure 5 floats freely on the surface of the water. The retaining elements 11 are fixed to the guide device 15 by means of cables or shackles. Once the object 1 has been positioned, the underwater sound damper 4 is closed. After closing said damper, the floor element 12 is lowered. The underwater sound damper 4 is preferably opened and closed above the water surface, the sound-reducing elements 10 not obtaining any buoyancy.
[0088] FIG. 26 shows a particular embodiment of an underwater sound damper 4 , in which a floor element 12 has been set down on the underwater floor 2 . Numerous support structures 5 that comprise sound-reducing elements 10 and are also independent of one another are arranged on said floor element 12 . The support structures 5 are connected to the floor element 12 by means of their lower ends 8 , which prevents the support structures 5 and the sound-reducing elements 10 rising any more. The support structures 5 consist of individual cables or of narrow net strips or are individual net tubes, in the interior of which the sound-reducing elements 10 are arranged. Each of the support structures 5 comprises a side edge 6 facing the adjacent support structures 5 . This embodiment of the underwater sound damper 4 is separated in multiple places and can therefore be easily penetrated, since the upper ends 7 of the support structures 5 are free and give way to a passing object 1 .
[0089] While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive. It will be understood that changes and modifications may be made by those of ordinary skill within the scope of the following claims. In particular, the present invention covers further embodiments with any combination of features from different embodiments described above and below. Additionally, statements made herein characterizing the invention refer to an embodiment of the invention and not necessarily all embodiments.
[0090] The terms used in the claims should be construed to have the broadest reasonable interpretation consistent with the foregoing description. For example, the use of the article “a” or “the” in introducing an element should not be interpreted as being exclusive of a plurality of elements. Likewise, the recitation of “or” should be interpreted as being inclusive, such that the recitation of “A or B” is not exclusive of “A and B,” unless it is clear from the context or the foregoing description that only one of A and B is intended. Further, the recitation of “at least one of A, B, and C” should be interpreted as one or more of a group of elements consisting of A, B, and C, and should not be interpreted as requiring at least one of each of the listed elements A, B, and C, regardless of whether A, B, and C are related as categories or otherwise. Moreover, the recitation of “A, B, and/or C” or “at least one of A, B, or C” should be interpreted as including any singular entity from the listed elements, e.g., A, any subset from the listed elements, e.g., A and B, or the entire list of elements A, B, and C. | A hydraulic noise suppressor for reducing water-borne noise, and method for handling the same, especially in the area of a construction site when an object is driven into underwater soil. The hydraulic noise suppressor can have at least two rigid holding elements, at least one support structure, and noise reducing elements secured to the at least one support structure, an upper end of the at least one support structure being secured to at least one of the at least two holding elements. The hydraulic noise suppressor can be divided along lateral flanks extending between the upper end and an opposite lower end of the at least one support structure. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of pending U.S. application Ser. No. 10/604,631 filed Aug. 6, 2003, which in turn is a continuation of U.S. application Ser. No. 10/064,730 filed Aug. 12, 2002, now U.S. Pat. No. 6,604,468 issued Aug. 12, 2003, which in turn is a continuation of U.S. application Ser. No. 09/341,395 filed Jul. 8, 1999, now U.S. Pat. No. 6,431,073 issued Aug. 13, 2002, which is a U.S. national stage application based on PCT/US98/00718 filed Jan. 14, 1998. U.S. Ser. No. 09/341,395 is in turn is a continuation of U.S. application Ser. No. 08/786,096 filed Jan. 17, 1997, now U.S. Pat. No. 5,769,034 issued Jun. 23, 1998.
BACKGROUND OF INVENTION
[0002] This disclosure relates generally to the field of boiler/furnace deslagging, and particularly, discloses a device, system and method allowing on-line, explosives-based deslagging.
[0003] A variety of devices and methods are used to clean slag and similar deposits from boilers, furnaces, and similar heat exchange devices. Some of these rely on chemicals or fluids that interact with and erode deposits. Water cannons, steam cleaners, pressurized air, and similar approaches are also used. Some approaches also make use of temperature variations. And, of course, various types of explosive, creating strong shock waves to blast slag deposits off of the boiler, are also very commonly used for deslagging.
[0004] The use of explosive devices for deslagging is a particularly effective method, as the large shock wave from an explosion, appropriately positioned and timed, can easily and quickly separate large quantities of slag from the boiler surfaces. But the process is costly, since the boiler must be shut down (i.e. brought off line) in order to perform this type of cleaning, and valuable production time is thereby lost. This lost time is not only the time during which the cleaning process is being performed. Also lost are several hours prior to cleaning when the boiler must be taken off line to cool down, and several hours subsequent to cleaning for the boiler to be restarted and brought into full operational capacity.
[0005] Were the boiler to remain on-line during cleaning, the immense heat of the boiler would prematurely detonate any explosive placed into the boiler, before the explosive has been properly positioned for detonation, rendering the process ineffective and possibly damaging the boiler. Worse, loss of control over the precise timing of detonation would create a serious danger for personnel located near the boiler at the time of detonation. So, to date, it has been necessary to shut down any heat exchange device for which explosives-based deslagging is desired.
[0006] Several U.S. patents have been issued on various uses of explosives for deslagging. U.S. Pat. Nos. 5,307,743 and 5,196,648 disclose, respectively, an apparatus and method for deslagging wherein the explosive is placed into a series of hollow, flexible tubes, and detonated in a timed sequence. The geometric configuration of the explosive placement, and the timing, are chosen to optimize the deslagging process.
[0007] U.S. Pat. No. 5,211,135 discloses a plurality of loop clusters of detonating cord placed about boiler tubing panels. These are again geometrically positioned, and detonated with certain timed delays, to optimize effectiveness.
[0008] U.S. Pat. No. 5,056,587 similarly discloses placement of explosive cord about the tubing panels at preselected, appropriately spaced locations, and detonation at preselected intervals, once again, to optimize the vibratory pattern of the tubing for slag separation.
[0009] Each of these patents discloses certain geometric configurations for placement of the explosive, as well as timed, sequential detonation, so as to enhance the deslagging process. But in all of these disclosures, the essential problem remains. If the boiler were to remain on-line during deslagging, the heat of the boiler would cause the explosive to prematurely detonate before it is properly placed, and this uncontrolled explosion will not be effective, may damage the boiler, and could cause serious injury to personnel.
[0010] U.S. Pat. No. 2,840,365 appears to disclose a method for introducing a tube into “a hot space such as an oven or a slag pocket for an oven” prior to the formation of deposits in the hot space; continuously feeding a coolant through the tube during the formation of deposits in the hot space, and, when it is time to break the deposits, inserting an explosive into the tube after the formation of the deposits while the tube is still somewhat cooled, and detonating the explosive before it has a chance to heat up and undesirably self-detonate. (See, e.g., col. 1, lines 44-51, and claim 1 ) There are a number of problems with the invention disclosed by this patent.
[0011] First, the hot space according to this patent must be thoroughly prepared and preconfigured, in advance, for the application of this method, and the tubes that contain the coolant and later the explosive, as well as the coolant feeding and discharge system, must be in place on a more or less permanent basis. The tubes are “inserted before the deposits begin to form or before they are formed sufficiently to cover the points where one wishes to insert the tubes” and are “cooled by the passage of a cooling fluid . . . therethrough during operation.” (col. 2, lines 26-29 and col. 1, lines 44-51) It is necessary “to provide sealable holes in several bricks for allowing the tube . . . to be inserted, or . . . to remove the bricks during operation of the furnace so that a hole is formed through which the tube may be inserted.” (col. 2, lines 32-36) The tubes are supported “at the back end of the pocket upon supports made for the purpose, e.g., by a stepped shape of the back of the wall . . . [or] at the front end or in front of and in the wall . . . [or by having] at least the higher tubes . . . rest immediately upon the deposits already formed.” (col. 2, lines 49-55) A complicated series of hoses and ducts are attached for “feeding cooling water . . . and discharging said cooling water.” (col. 3, lines 1-10, and FIG, 2 generally) And, the tubes must be cooled whenever the hot space is in operation to prevent the tubes from burning and the water from boiling. (see, e.g., col. 3 lines 14-16 and col. 1, lines 44-51) In sum, this invention cannot simply be brought onto the site of a hot space after deposits have formed and then used at will to detonate the deposits while the hot space is still hot. Rather, the tubes must be in place and continuously cooled essentially throughout the entire operation of the hot space and the accumulation of deposits. And, significant accommodations and preparation such as tube openings and supports, the tubes themselves, and coolant supply and drainage infrastructure, must be permanently established for the associated hot space.
[0012] Second, the method disclosed by this patent is dangerous, and must be performed quickly to avoid danger. When the time arrives to break the slag deposits, “the pipes . . . are drained,” various cocks, hoses, bolts and an inner pipe are loosened and removed, and “explosive charges are now inserted [into the pipe] . . . immediately after termination of the cooling so that no danger of self-detonation exists, because the explosive charges cannot become too hot before being exploded intentionally.” (col. 3, lines 17-28) Then, the “tubes are exploded immediately after stopping the cooling at the end of the operation of the furnace . . . ” (col. 1, lines 49-51) Not only is the process of draining the pipe and readying it to receive the explosive fairly cumbersome, it must also be done in a hurry to avoid the danger of premature explosion. As soon as the coolant flow is ceased, time is of the essence, since the tubes will begin to heat up, and the explosives must be placed into the tubes and purposefully detonated quickly, before the heating of the tube become so great that the explosive accidentally self-detonates. There is nothing in this patent that discloses or suggests how to ensure that the explosive will not self-detonate, so that the process does not have to be unnecessarily hurried to avoid premature detonation.
[0013] Third, the pre-placement of the tubes as discussed above constrains the placement of the explosive when the time for detonation arrives. The explosives must be placed into the tubes in their preexisting location. There is no way to simply approach the hot space after the slag accumulation, freely choose any desired location within the hot space for detonation, move an explosive to that location in an unhurried manner, and then freely and safely detonate the explosive at will.
[0014] Fourth, it may be inferred from the description that there is at least some period of time during which the hot space must be taken out of operation. Certainly, operation must cease long enough for the site to be prepared and fitted to properly utilize the invention as described earlier. Since one object of the invention is to “prevent the oven . . . to be taken out of operationfor too long a time,” (col. 1, lines 39-41, emphasis added), and, since the “tubes are exploded immediately after stopping the cooling at the end of the operation of the furnace or the like” (col. 1, lines 49-51, emphasis added), it appears from this description that the hot space is in fact shut down for at least some time prior to detonation, and that the crux of the invention is to hasten the cooling of the slag body after shutdown so that detonation can proceed more quickly without waiting for the slag body to cool down naturally (see col. 1, lines 33-36), rather than to allow detonation to occur while the hot space is in full operation without any shutdown at all.
[0015] Finally, because of all the site preparation that is needed prior to using this invention, and due to the configuration shown and described for placing the tubes, this invention does not appear to be usable across the board with any form of hot space device, but only with a limited type of hot space device that can be readily preconfigured to support the disclosed horizontal tubing structure as disclosed.
[0016] Luxemburg Pat. No. 41,977 has similar problems to U.S. Pat. No. 2,840,365, particularly: insofar as this patent also requires a significant amount of site preparation and preconfiguration before the invention disclosed thereby can be used; insofar as one cannot simply approach the hot space after the slag accumulation, freely choose any desired location within the hot space for detonation, move an explosive to that location in an unhurried manner, and then freely and safely detonate the explosive at will; and insofar as the types of hot space devices to which this patent applies also appear to be limited.
[0017] According to the invention disclosed by this patent, a “blasting hole” must be created within the subject hot space before the invention can be used. (translation of page 2, second full paragraph) Such holes are “drilled at the time of need or made prior to the formation of the solid mass.” (translation of paragraph beginning on page 1 and ending on page 2) Since the device for implementing the process of the invention “includes at least a tube that permits feeding the cooling fluid into the bottom of the blasting hole” (translation of page 2, fourth full paragraph) and, in one form of implementation, “a retaining plate . . . positioned at the bottom of the blast hole (translation of paragraph beginning on page 2 and ending on page 3), and since it is a key feature of the invention that the blast hole is filled with coolant prior to and during the insertion of the explosive, it may be inferred from this description that the blast hole is substantially vertical in it orientation, or at least has a significant enough vertical component to enable water to effectively accumulate and pool within the blast hole.
[0018] Because the subject hot space must be preconfigured with a blast hole or holes (with implicitly at least a substantial vertical component) before this invention can be used, it is again not possible to simply approach an unprepared hot space at will after deposits have accumulated, and detonate at will. Since the coolant and the explosive must be contained within the blast holes, it is not possible to freely move and position the explosive wherever desired within the hot space. The explosives can only be positioned and detonated within the blast holes pre-drilled for that purpose. Due to the at least partially vertical orientation of the blast holes, the angle of approach for introducing the coolant and the explosive is necessarily constrained. Also, while it is not clear from the disclosure how the blast holes are initially drilled, it appears that at least some amount of boiler shutdown and/or disruption would be required to introduce these blast holes.
[0019] Finally, in both of these cited patents, the components which hold the coolant (the tubes for U.S. Pat. No. 2,840,365 and the blast holes for LU 41,977) reside within the hot space, and are already very hot when the time arrives to deslag. The object of both of these patents, is to cool these components down before the explosive is introduced. U.S. Pat. No. 2,840,365 achieves this by virtue of the fact that the tubes are continuously cooled throughout the operation of the hot space, which, again, is very disruptive and requires significant preparation of and modification to the hot space. And LU 41,977 clearly states that “[a]ccording to all its forms of implementation, the device is put in place without a charge for the purpose of cooling the blast hole for a few hours with the injection fluid. (translation of page 4, last full paragraph, emphasis added) It would be desirable to avoid this cool down period altogether and therefor save time in the deslagging process, and to simply introduce a cooled explosive into a hot space at will without any need to alter or preconfigure the boiler, and to then detonate the cooled explosive at will once it has been properly placed in whatever detonation location is desired. And most certainly, the application of LU 41,977 is limited only to hot spaces into which it is feasible to introduce a blast hole, which appears to eliminate many types of heat-exchange device into which it is not feasible to introduce a blast hole.
[0020] It would be desirable if a device, system and method could be devised which would allow explosives to safely and controllably be used for deslagging, on-line, without any need to shut down the boiler during the deslagging process. By enabling a boiler or similar heat-exchange device to remain on-line for explosives-based deslagging, valuable operations time for fuel-burning facilities could then be recovered.
[0021] It is therefore desired to provide a device, system and method whereby explosives may be used to clean a boiler, furnace, scrubber, or any other heat exchange device, fuel burning, or incinerating device, without requiring that device to be shut down, thereby enabling that device to remain in full operation during deslagging.
[0022] It is desired to enable valuable operations time to be recovered, by virtue of eliminating the need for shutdown of the device or facility to be cleaned.
[0023] It is desired to enhance personnel safety and facility integrity, by enabling this on-line explosives-based cleaning to occur in a safe and controlled manner.
SUMMARY OF INVENTION
[0024] This invention enables explosives to be used for cleaning slag from a hot, on-line boiler, furnace, or similar fuel-burning or incineration device, by delivering a coolant to the explosive which maintains the temperature of the explosive well below what is required for detonation. The explosive, while it is being cooled, is delivered to its desired position inside the hot boiler without detonation. It is then detonated in a controlled manner, at the time desired.
[0025] While many obvious variations may occur to someone of ordinary skill in the relevant arts, the preferred embodiment disclosed herein uses a perforated or semi-permeable membrane which envelopes the explosive and the cap or similar device used to detonate the explosive. A liquid coolant, such as ordinary water, is delivered at a fairly constant flow rate into the interior of the envelope, thereby cooling the external surface of the explosive and maintaining the explosive well below detonation temperature. Coolant within the membrane in turn flows out of the membrane at a fairly constant rate, through perforations or microscopic apertures in the membrane. Thus cooler coolant constantly flows into the membrane while hotter coolant that has been heated by the boiler flows out of the membrane, and the explosive is maintained at a temperature well below that needed for detonation. Coolant flow rates typical of the preferred embodiment run between 20 and 80 gallons per minute.
[0026] This coolant flow is initiated as the explosive is first being placed into the hot boiler. Once the explosive has been moved into the proper position and its temperature maintained at a low level, the explosive is detonated as desired, thereby separating the slag from, and thus cleaning, the boiler.
BRIEF DESCRIPTION OF DRAWINGS
[0027] The features of the invention believed to be novel are set forth in the appended claims. The invention, however, together with further objects and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawing(s) in which:
[0028] FIG. 1 depicts the preferred embodiment of a device, system and method used to perform on-line cleaning of a fuel-burning facility.
[0029] FIG. 2 depicts the device in its disassembled (preassembly) state, and is used to illustrate the method by which this device is assembled for use.
[0030] FIG. 3 illustrates the use of the assembled cleaning device to clean an on-line fuel burning or incineration facility.
[0031] FIG. 4 depicts an alternative preferred embodiment of this invention, which reduces coolant weight and enhances control over coolant flow, and which utilizes remote detonation.
DETAILED DESCRIPTION
[0032] FIG. 1 depicts the basic tool used for on-line cleaning of a fuel-burning facility such as a boiler, furnace, or similar heat exchange device, or an incineration device, and the discussion following outlines the associated method for such on-line cleaning.
[0033] The cleaning of the fuel burning and/or incineration facility is carried out in the usual manner by means of an explosive device 101 , such as but not limited to an explosive stick or other explosive device or configuration, placed appropriately inside the facility, and then detonated such that the shock waves from the explosion will cause slag and similar deposits to dislodge from the walls, tubing, etc. of the facility. This explosive device 101 is detonated by a standard explosive cap 102 or similar detonating device, which causes controlled detonation at the desired instant, based on a signal sent from a standard initiator 103 , by a qualified operator.
[0034] However, to enable explosives-based cleaning to be performed on-line, i.e., with any need to power down or cool down the facility, two prior art problems must be overcome. First, since explosives are heat-sensitive, the placement of an explosive into a hot furnace can cause premature, uncontrolled detonation, creating danger to both the facility and personnel around the explosion. Hence, it is necessary to find a way of cooling the explosive while it is being placed in the on-line facility and readied for detonation. Second, it is not possible for a person to physically enter the furnace or boiler to place the explosive, due the immense heat of the on-line facility. Hence, it is necessary to devise a means of placing the explosive that can be managed and controlled from outside the burner or furnace.
[0035] In order to properly cool the explosive, a cooling envelope 104 is provided which completely envelopes the explosive. During operation, this envelope will have pumped into it a coolant, such as ordinary water, that will maintain the explosive device 101 in a cooled-down state until it is ready for detonation. Because of the direct contact between the coolant and the explosive device 101 , this device is ideally made of a plastic or similar waterproof housing that contains the actual explosive powder or other explosive material.
[0036] This cooling envelope 104 is a semi-permeable membrane that allows water to flow out of it at a fairly controlled rate. It can have a series of small perforations punched into it, or can be constructed of any semi-permeable membrane material appropriate to its coolant-delivery function as will outlined herein. This semi-permeability characteristic is illustrated by the series of small dots 105 scattered throughout the envelope 104 as depicted in FIG. 1 .
[0037] At an open end (coolant entry opening), the envelope 104 is attached to a coolant delivery pipe 106 via an envelope connector 107 . As depicted here, the envelope connector 107 is cone-shaped apparatus permanently affixed to the coolant delivery pipe 106 , and it further comprises a standard threading 108 . The envelope itself, at this open end, is fitted and permanently affixed to complementary threading (not shown) that is easily screwed into and fitted with the threading 108 of the connector 107 . While FIG. 1 depicts screw threads in connection with a cone-shaped apparatus as the particular means of attaching the envelope 104 to the coolant delivery pipe 106 , any type of clamp, and indeed, many other means of attachment know to someone of ordinary skill would also be provide a feasible and obvious alternative, and such substitutions for attaching the envelope 104 to the pipe 106 are fully contemplated to be within the scope of this disclosure and its associated claims.
[0038] The coolant delivery pipe 106 , in the region where said pipe resides within the envelope 104 , further contains a number of coolant delivery apertures 109 , twin ring holders 110 , and an optional butt plate 111 . The explosive device 101 with cap 102 is affixed to one end of an explosive connector (broomstick) 112 with explosive-to-broomstick attachment means 113 such as duct tape, wire, rope, or any other means that provides a secure attachment. The other end of the broomstick is slid through the twin ring holders 110 until it abuts the butt plate 111 , as shown. At that point, the broomstick, optionally, may be further secured by means of, for example, a bolt 114 and wingnut 115 running through both the broomstick 112 and the pipe 106 as depicted. While the rings 110 , butt plate 111 , and nut and bolt 115 and 114 provide one way to secure the broomstick 112 to the pipe 106 , many other ways to secure the broomstick 112 to the pipe 106 can also be devised by someone of ordinary skill, all of which are contemplated within the scope of this disclosure and its related claims. The length of the broomstick 112 may vary, though for optimum effectiveness, it should maintain the explosive 101 at approximately two or more feet from the end of the pipe 106 that contains the coolant delivery apertures 109 , which, since it is desirable to reuse the pipe 106 and its components, will minimize any possible damage to the pipe 106 and said components when the explosive is detonated, and will also reduce any shock waves sent back down the pipe to the operator of this invention.
[0039] With the configuration disclosed thus far, a coolant such as water under pressure entering the left side of the pipe 106 as depicted in FIG. 1 will travel through the pipe and exit the pipe through the coolant delivery apertures 109 in a manner illustrated by the directional flow arrows 116 . Upon exiting the pipe 106 through the apertures 109 , the coolant then enters the inside of the envelope 104 and begins to fill up and expand the envelope. As the coolant fills the envelope, it will come into contact with and cool the explosive device 101 . Because the envelope 104 is semi-permeable ( 105 ), water will also exit the envelope as the envelope becomes full as shown by the directional arrows 116 a, and so the entry under pressure of new water into the pipe 106 combined with the exit of water through the semipermeable ( 105 ) envelope 104 , will deliver a continuous and stable flow of coolant to the explosive device 101 .
[0040] The entire cooling and cleaning delivery assembly 11 disclosed thus far, is in turn connected to a coolant supply and explosive positioning system 12 as follows. A hose 121 with water service (for example, but not limited to, a standard ¾″ Chicago firehose and water service) is attached to a hydraulic tube 122 (e.g. pipe) using any suitable hose attachment fitting 123 . The coolant, preferable ordinary water, runs under pressure through the hose as indicated by the directional flow arrow 120 . The end of the tube 122 opposite the hose 121 contains attachment means 124 such as screw threading, which complements and joins with similar threading 117 on the pipe 106 . Of course, any means known to someone of ordinary skill for joining the tube 122 and pipe 106 in the manner suggested by the arrow 125 in FIG. 1 , such that coolant can run from the hose 121 through the tube 122 , into the pipe 106 , and finally into the envelope 104 , is acceptable and contemplated by this disclosure and its associated claims.
[0041] Finally, detonation is achieved by electrically connecting the explosive cap 102 to the initiator 103 . This is achieved by connecting the initiator 103 to a lead wire pair 126 , in turn connecting to a second lead wire pair 118 , in turn connecting to a cap wire pair 119 . This cap wire pair 119 is finally connected to the cap 102 . The lead wire pair 126 enters the tube 122 from the initiator 103 through a lead wire entry port 127 as shown, and then runs through the inside of the tube 122 , and out the far end of the tube. (This entry port 127 can be constructed in any manner obvious to someone of ordinary skill, so long as it enables the wire 126 to enter the tube 122 and averts any significant coolant leakage.) The second lead wire pair 118 runs through the inside of the pipe 106 , and the cap wire pair 119 is enclosed within the envelope 104 as shown. Thus, when the initiator 103 is activated by the operator, an electrical current flows straight to the cap 102 , detonating the explosive 101 .
[0042] While FIG. 1 thus depicts electronic detonation of the cap and explosive via a hard wire signal connection, it is contemplated that any alternative means of detonation known to someone of ordinary skill could also be employed, and is encompassed by this disclosure and its associated claims. Thus, for example, detonation by a remote control signal connection between the initiator and cap (which will be further discussed in FIG. 4 ), eliminating the need for the wires 126 , 118 , and 119 , is very much an alternative preferred embodiment for detonation. Similarly, non-electronic shock (i.e. percussion), and heat-sensitive detonation can also be used within the spirit and scope of this disclosure and its associated claims.
[0043] While any suitable liquid can be pumped into this system as a coolant, the preferred coolant is ordinary water. This is less expensive than any other coolant, it performs the necessary cooling properly, and it is readily available at any site which has a pressurized water supply that may be delivered into this system. Notwithstanding this preference for ordinary water as the coolant, this disclosure contemplates that many other coolants known to someone of ordinary skill can also be used for this purpose as well, and all such coolants are regarded to be within the scope of the claims.
[0044] At this point, we turn to discuss methods by which the on-line cleaning device disclosed above is assembled for use and then used. FIG. 2 shows the preferred embodiment of FIG. 1 in preassembly state, disassembled into its primary components. The explosive 101 is attached to the cap 102 , with the cap in turn connected to the one end of the cap wire pair 119 . This assembly is attached to one end of the broomstick 112 using the explosive-to-broomstick attachment means 113 such as duct tape, wire, rope, etc., or any other approach known to someone of ordinary skill, as earlier depicted in FIG. 1 . The other end of the broomstick 112 is slid into the twin ring holders 110 of the pipe 106 until it abuts the butt plate 111 , also as earlier shown in FIG. 1 . The bolt 114 and nut 115 , or any other obvious means, may be used to further secure the broomstick 112 to the pipe 106 . The second lead wire pair 118 is attached to the remaining end of the cap wire pair 119 to provide an electrical connection therebetween. Once this assemblage has been achieved, the semipermeable ( 105 ) cooling envelope 104 is slid over the entire assembly, and attached to the envelope connector 107 using the threading 108 , clamp, or any other obvious attachment means, as depicted in FIG. 1 .
[0045] The right-hand side (in FIG. 2 ) of lead wire pair 126 is attached to the remaining end of the second lead wire pair 118 providing an electrical connection therebetween. The pipe 106 is then attached to one end of the hydraulic tube 122 as also discussed in connection with FIG. 1 , and the hose 121 is hooked to the other end of the tube 122 , completing all coolant delivery connections. The initiator 103 is attached to the remaining end of the lead wire pair 126 forming an electrical connection therebetween, and completing the electrical connection from the initiator 103 to the cap 102 .
[0046] When all of the above connections have been achieved, the on-line cleaning device is fully assembled into the configuration shown in FIG. 1 .
[0047] FIG. 3 now depicts the usage of this fully assembled on-line cleaning device, to clean a fuel burning facility 31 such as a boiler, furnace, scrubber, incinerator, etc., and indeed any fuel-burning or refuse-burning device for which cleaning by explosives is suitable. Once the cleaning device has been assembled as discussed in connection with FIG. 2 , the flow 120 of coolant through the hose 121 is commenced. As the coolant passes through the hydraulic tube 122 and pipe 106 , it will emerge from the coolant apertures 109 to fill the envelope 104 and provide a flow of coolant (e.g. water) to surround the explosive 101 , maintaining the explosive at a relatively cool temperature. Optimal flow rates range between approximately 20 and 80 gallons per minute.
[0048] Once this flow is established and the explosive is maintained in a cool state, the entire cooling and cleaning delivery assembly 11 is placed into the on-line facility 31 through an entry port 32 such as a manway, handway, portal, or other similar means of entry, while the coolant supply and explosive positioning system 12 remains outside of said facility. At a location near where assembly 111 meets system 12 , the pipe 106 or tube 122 is rested against the bottom of the entry port 32 at the point designated by 33 . Because the coolant pumped through the envelope 104 introduces a fair amount of weight into assembly 111 (with some weight also added to the system 12 ), a downward force designated by 34 is exerted to the system 12 , with the point 33 acting as the fulcrum. Applying appropriate force 34 and using 33 as the fulcrum, the operator positions the explosive 101 to the position desired. It is further possible to place a fulcrum fitting device (not shown) at location 33 , so as to provide a stable fulcrum and also protect the bottom of the port 32 from the significant weight pressure that will be exerted at the fulcrum. Throughout this time, new (cooler) coolant is constantly flowing into the system while older (hotter) coolant which has been heated by the on-line facility exits via the semipermeable envelope 104 , so that this continued flow of coolant into the system maintains the explosive 101 in a cool state. Finally, when the operator has moved the explosive 101 in the desired position, the initiator 103 is activated to initiate the explosion. This explosion creates a shock wave in region 35 , which thereby cleans and deslags that region of the boiler or similar facility, while the boiler/facility is still hot and on-line.
[0049] Referring back to FIG. 2 , during the explosion, the explosives 101 , cap 102 , cap wire 119 , broomstick 112 , and broomstick attachment means 113 are all destroyed by the explosion, as is the envelope 104 . Thus, it is preferable to fabricate the broomstick 112 out of wood or some other material that is extremely inexpensive and disposable after a single use. Similarly, the envelope 104 , which is for a single use only, should be fabricated from a material that is inexpensive, yet durable enough to maintain physical integrity while water is being pumped into it under pressure. And of course, this envelope 104 must be semi-permeable ( 105 ), which can be achieved, for example, by using any appropriate membrane which in essence acts as a filter, either with a limited number of macroscopic puncture holes, or a large number of fine, microscopic holes.
[0050] On the other hand, all other components, particularly the pipe 106 and all of its components 107 , 108 , 109 , 110 , 111 , and 118 , as well as the bolt 114 and nut 115 , are reusable, and so should be designed from materials that provide proper durability in the vicinity of the explosion. (Again, note that the length of the broomstick 112 determines the distance of the pipe 106 and its said components from the explosion, and that approximately two feet or more is a desirable distance to impose between the explosive 101 and any said component of the pipe 106 .)
[0051] Additionally, because coolant filling the envelope 104 adds significant weight to the right of the fulcrum 33 in FIG. 3 , the materials used to construct the cleaning delivery assembly 11 should be as lightweight as possible so long as they can endure both the heat of the furnace and the explosion (the envelope 104 should be as light as possible yet resistant to any possible heat damage), while to counterbalance the weight of 11, the coolant supply and explosive positioning system 12 may be constructed of heavier materials, and may optionally include added weight simply for ballast. Water weight can also be counterbalanced by lengthening the system 12 so that force 34 can be applied farther from the fulcrum 33 . And of course, although the system 12 is shown here as embodying a single tube 122 , it is obvious that this assembly can also be designed to employ a plurality of tubes attached to one another, and can also be designed so as to telescope from a shorter tube into a longer tube. All such variations, and others that may be obvious to someone of ordinary skill, are fully contemplated by this disclosure and included within the scope of its associated claims.
[0052] FIG. 4 depicts an alternative preferred embodiment of this invention with reduced coolant weight and enhanced control over coolant flow, and remote detonation.
[0053] In this alternative embodiment, the cap 102 now detonates the explosive 101 by a remote control, wireless signal connection 401 sent from the initiator 103 to the cap 102 . This eliminates the need for the lead wire entry port 127 that was shown in FIG. 1 on the tube 122 , as well as the need to run the wire pairs 126 , 118 and 119 through the system to carry current from the initiator 103 to the cap 102 .
[0054] FIG. 4 further shows a modified envelope 104 ′, which is narrower where the coolant first enters from the pipe 106 and wider in the region 402 of the explosive 101 . Additionally, this envelope is impermeable in the region where coolant first enters the pipe, and permeable ( 105 ) only in the region near the explosive 101 . This modification achieves two results.
[0055] First, since a main object of this invention is to cool the explosive 101 so that it can be introduced into an on-line fuel-burning facility, it is desirable to make the region of the envelope 104 ′ where the explosive is not present as narrow as possible, thus reducing the water weight in this region and making it easier to achieve a proper weight balance about the fulcrum, as discussed in connection with FIG. 3 . Similarly, by broadening the envelope 104 ′ near the explosive 101 , as shown by 402 , a greater volume of coolant will reside in precisely the area that it is needed to cool the explosive 101 , thus enhancing cooling efficiency.
[0056] Second, since it desirable for hotter coolant that has been in the envelope for a period of time to leave the system in favor of cooler coolant being newly introduced into the envelope, the impermeability of the entry region and midsection of the envelope 104 ′ will enable all newly-introduced coolant to reach the explosive before that coolant is allowed to exit the envelope 104 ′ from its permeable ( 105 ) section 402 . Similarly, the coolant in the permeable region of the envelope will typically have been in the envelope longest, and will therefore be the hottest. Hence, the hotter coolant leaving the system is precisely the coolant that should be leaving, while the cooler coolant cannot exit the system until it has traveled through the entire system and thus become hotter and therefore ready to leave.
[0057] While the disclosure thus far has discussed the preferred embodiment, it will be obvious to someone of ordinary skill that there are many alternative embodiments for achieving the result of the disclosed invention. For example, although a liner, stick configuration and a single explosive device was discussed here, any other geometric configuration of explosives, including a plurality of explosive devices, and/or including the introduction of various delay timing features as among such a plurality of explosive devices, is also contemplated within the scope of this disclosure and its associated claims. This would include, for example, the various explosive configurations such as those disclosed in the various U.S. Patents earlier-cited herein, wherein these explosive configurations are provided a similar means by which a coolant can be delivered to the explosive in such a way as to permit on-line detonation. In short, it is contemplated that the delivery of coolant to one or more explosive devices by any means obvious to someone of ordinary skill, enabling those explosive devices to be introduced into an on-line fuel-burning facility and then simultaneously or serially detonated in a controlled manner, is contemplated by this disclosure and covered within the scope of its associated claims.
[0058] Further, while only certain preferred features of the invention have been illustrated and described, many modifications, changes and substitutions will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. | A device, system and method permitting on-line explosives-based cleaning and deslagging of a fuel burning facility ( 31 ) such as a boiler, furnace, incinerator, or scrubber. A coolant, such as ordinary water, is delivered to the explosives ( 101 ) to prevent them from detonating due to the heat of the on-line facility. Thus, controlled, appropriately-timed detonation can be initiated as desired, and boiler scale and slag is removed without the need to shut down or cool down the facility. | 1 |
BACKGROUND OF THE INVENTION
This invention describes a fiber treatment agent. More specifically, this invention describes a fiber treatment composition which can impart to fiber materials a durable antistaticity, moisture absorbability and perspiration absorbability, resistance to soiling, rebound elasticity, flexibility, smoothness, creaseproofness and compression recovery.
Various organopolysiloxanes and treatment agents composed of these organopolysiloxanes which can impart flexibility, smoothness, creaseproofness and recovery to fiber materials have been employed and proposed to date.
For example, a dimethylpolysiloxane oil and its emulsion have been employed to provide flexibility. Also, a treatment agent composed of a methylhydrogenpolysiloxane, a hydroxyl group-terminated dimethylpolysiloxane and a condensation reaction catalyst has been employed to provide durable flexibility, creaseproofness and recovery. Of more relevance to the present invention, Japanese Pat. No. 48-17514 [73-17514] describes a treatment agent composed of an organopolysiloxane which possesses at least 2 epoxy groups per molecule and an amino group-containing organopolysiloxane for imparting smoothness to organic synthetic fibers; Japanese Pat. No. 53-36079 [78-36079] describes a treatment agent composed of a hydroxyl group-terminated diorganopolysiloxane, an organosilane, which contains both amine and alkoxy groups in each molecule, and/or its partial hydrolyzate and condensate; Japanese Pat. Nos. 53-19715 [78-19715] and 53-19716 [-19716] describe a treatment agent composed of an aminoalkyltrialkoxysilane and an epoxy group-containing organopolysiloxane; and Japanese Kokai Pat. No. 53-98499 [78-98499] proposes a triorganosiloxy group-terminated diorganopolysiloxane which possesses at least 2 aminoalkyl groups per molecule.
However, the prior art treatment agents cited above exhibit various drawbacks. For example, the treatment agent in which the principal agent is a dimethylpolysiloxane oil provides an unsatisfactory creaseproofness and recovery and the flexibility and smoothness are not durable. The treatment agent in which a methylhydrogenpolysiloxane is the essential component does not undergo an adequate curing reaction in the absence of a catalyst while the life span of its treatment bath is short in the presence of a catalyst. Also, it generates a large amount of hydrogen gas which is a dangerous fire or explosion risk. The treatment agent in which the principal agents are an epoxy group-containing organopolysiloxane and an amino group-containing organopolysiloxane suffers from the generation of a large amount of static electricity due to friction, the ready adhesion of oily soils and a reduced moisture absorbability and perspiration absorbability in the treatment of underwear. In order to eliminate the above drawbacks, a hydrophilic surfactant, e.g., the salt of a sulfate ester of ricinoleic acid, Turkey red oil, polysiloxane-polyoxyalkylene copolymers or the polyoxyethylene adduct of higher alcohols, is conventionally added to the treatment agent. However, these surfactants are readily soluble in water or in the organic solvents used in dry cleaning and are easily removed by repeated washing with the result that they exhibit the drawback of a lack of durability.
BRIEF SUMMARY OF THE INVENTION
Various methods were examined by the present inventors in order to eliminate the drawbacks of prior art fiber treatment agents and a fiber treatment agent was discovered which can impart a durable antistaticity, moisture absorbability and perspiration absorbability, resistance to soiling, rebound elasticity, flexibility, smoothness, creaseproofness and compression recovery to fibers.
Briefly stated this discovery relates to an aqueous emulsion comprising a mixture of (a) an aminoorgano-substituted organopolysiloxane and (b) an alkoxysilane which bears certain hydrophilic groups and to a method for treating a fiber material therewith. The organopolysiloxane moiety of component (a) imparts flexibility and smoothness to fibers and the amino group of component (a) provides good absorption to fibers so that it imparts a smoothness, flexibility and lubricity. The alkoxy group of component (b) serves to crosslink component (b) with the hydroxyl or alkoxy end group of component (a) in order to impart "firmness", compression recovery and rebound elasticity to fabrics and its hydrophilic group provides antistaticity and perspiration absorbability.
DETAILED DESCRIPTION OF THE INVENTION
In one aspect the present invention relates to an emulsion composition obtained by mixing components consisting essentially of (a) 100 parts by weight of an organopolysiloxane having a viscosity at 25° C. of at least 10 centistokes and having the general formula ##STR1## wherein R represents a monovalent hydrocarbon or halogenated hydrocarbon group having from 1 to 20 carbon atoms, R 1 represents a hydrogen atom or a monovalent hydrocarbon group, m and n are integers each with a value ≧ 1, A represents a hydroxyl group or an alkoxy group having from 1 to 5 carbon atoms , Q represents a divalent hydrocarbon group and a is an integer with a value of 0 to 5, (b) 1 to 100 parts by weight of a silane having the general formula (R 2 ) 3 Si--Z--O--R 3 wherein R 2 represents an alkoxy or alkoxyalkoxy group having from 1 to 5 carbon atoms, Z represents a divalent hydrocarbon group and R 3 represents a hydrogen atom, a hydroxyl group-containing alkyl group or a polyoxyalkylene group or a partial hydrolysis condensate of said silane, (c) 1 to 30 parts by weight of a surfactant selected from the group consisting of nonionic and cationic surfactants and (d) an emulsion-forming quantity of water.
In the formula for component (a) of the compositions of this invention each R represents a C 1-20 monovalent hydrocarbon or halogenated monovalent hydrocarbon group, such as alkyl, aryl, arylalkyl, alkaryl, alkenyl and cycloaliphatic groups and halogenated derivatives of these groups. Concrete examples of R include, but are not limited to, methyl, ethyl, propyl, butyl, pentyl, vinyl, 3,3,3-trifluoropropyl, cyclohexyl, chloropropyl, chloroisobutyl, phenyl and styryl. All the R groups in a single molecule need not be identical to each other. R is most commonly the methyl group, however, a combination of major amounts of the methyl group and minor amounts of other groups is also common.
In the formula for component (a) each R 1 represents a hydrogen atom or a monovalent hydrocarbon group, such as those denoted above for R, and A represents a hydroxyl group or a C 1-5 alkoxy group such as methoxy, typically, or ethoxy, which serves to crosslink component (a) with component (b).
In the formula for component (a) Q represents a divalent hydrocarbon group such as an alkylene group such as --CH 2 --, --CH 2 CH 2 --, --CH 2 CH 2 CH 2 --, --CH(CH 3 )CH 2 -- or, --CH 2 CH(CH 3 )CH 2 -- or --(CH 2 ) 4 -- or an arylene group such as --(CH 2 ) 2 C 6 H 4 --. Propylene and isobutylene are the most typical cases. Both m and n are integers with values of ≧1 and a is an integer with a value of 0 to 10, but it is usually 0 or 1.
Component (a) is preferably an aminofunctional methylsiloxane fluid having the formula ##STR2## The viscosity of component (a) at 25° C. is at least 10 centistokes (cSt), preferably from about 100 to 5,000 cSt and most preferably is 200 to 500 cSt in order to provide flexibility, smoothness, compression recovery and creaseproofness to a fiber material treated therewith.
Component (a) is a well-known material in the organosilicon art and can be easily produced by the method described in U.S. Pat. No. 4,247,592 which is incorporated by reference. For example, an alkoxysilane with the general formula H 2 N(CH 2 ) 3 Si(CH 3 )(OCH 3 ) 2 is hydrolyzed with excess water. The resulting hydrolysis condensation product is then equilibrated with a dimethylcyclopolysiloxane at elevated temperatures of 80 to 100° C. in the presence of a basic catalyst such as sodium hydroxide but in the absence of a chain terminating agent. The basic catalyst is neutralized with acid in the usual manner after the viscosity has reached the desired value.
In the formula for component (b) of the compositions of this invention each R 2 represents a C 1-5 alkoxy group such as methoxy, ethoxy, n-propoxy, isopropoxy, or an alkoxyalkoxy group such as methoxyethoxy. Methoxy and ethoxy are preferred R 2 groups. Component (b) preferably has the formula (MeO) 3 SiZOR 3 .
In the formula for component (b) Z represents a divalent hydrocarbon group, such as those denoted above for Q, and R 3 represents a hydrogen atom, a hydroxyl-group-containing alkyl groups such as --CH 2 CH 2 OH or a polyoxyalkylene group, such as polyoxyethylene or polyoxypropylene or polyoxyethyleneoxypropylene.
Component (b) is readily produced by the addition reaction of a silane having the general formula (R 2 ) 3 SiH, such as (CH 3 O) 3 SiH, with a compound having the general formula CH 2 ═CH(CH 2 ) 0-2 OR 3 , such as CH 2 ═CHCH 2 O(CH 2 CH 2 O) 10 H in the presence of a hydrosilylation catalyst such as chloroplatinic acid. In addition, component (b) may be combined with a small quantity of water and then possibly heated in order to carry out its partial hydrolysis or condensation.
In the compositions of this invention component (c) is a surfactant which can emulsify component (a) in water and concrete examples thereof are polyoxyalkylene alkyl ethers, polyoxyalkylene alkylphenol ethers, polyoxyalkylene alkyl esters, sorbitan alkyl esters, polyoxyalkylene sorbitan alkylesters, aliphatic amine salts, quaternary ammonium salts, alkylpyridinium salts and mixtures of 2 or more of these compounds. The quantity of addition of component (c) must be adequate to emulsify component (a) and this quantity is usually 1 to 30 parts by weight per 100 parts by weight of component (a).
Water which comprises component (d) is added in sufficient amount to form the emulsion compositions of this invention and its quantity of addition is not further limited. Preferably the fiber treating compositions of this invention contain at least about 90 percent by weight water.
A composition of this invention is produced by combining the organopolysiloxane component (a) with the surfactant component (c) and water component (d) in order to produce an emusion which is combined with component (b) immediately prior to use. Alternatively, the above emulsion is combined with an aqueous solution of component (b) dissolved in an aqueous solution of component (c).
The compositions of this invention may be combined with an aliphatic acid salt of a metal such as tin, zinc, lead or cobalt as a condensation reaction catalyst.
In a second aspect the present invention relates to a method comprising (I) forming an emulsion composition by mixing components consisting essentially of (a) 100 parts by weight of an organopolysiloxane having a viscosity at 25° C. of at least 10 centistokes and having the general formula ##STR3## wherein R represents a monovalent hydrocarbon or halogenated hydrocarbon group having from 1 to 20 carbon atoms, R 1 represents a hydrogen atom or a monovalent hydrocarbon group, m and n are integers each with a value ≧ 1, A represents a hydroxyl group or an alkoxy group having from 1 to 5 carbon atoms , Q represents a divalent hydrocarbon group and a is an integer with a value of 0 to 5, (b) 1 to 100 parts by weight of a silane having the general formula (R 2 ) 3 Si--Z--O--R 3 wherein R 2 represents an alkoxy or alkoxyalkoxy group having from 1 to 5 carbon atoms, Z represents a divalent hydrocarbon group and R 3 represents a hydrogen atom, a hydroxyl group-containing alkyl group or a polyoxyalkylene group or a partial hydrolysis condensate of said silane, (c) 1 to 30 parts by weight of a surfactant selected from the group consisting of nonionic and cationic surfactants and (d) an emulsion-forming quantity of water, (II) applying the emulsion composition onto a fiber material and (III) heating the applied emulsion composition sufficiently to accelerate a crosslinking reaction between component (a) and component (b).
In the method of this invention the emulsion composition that is applied to a fiber material is any of the emulsion compositions of this invention delineated herein, including preferred embodiments thereof.
The composition is applied onto a fiber material by any suitable method, such as spraying or immersion, dried by standing at room temperature or by heating and then heat-treated in order to accelerate the crosslinking reaction between the amino group-containing organopolysiloxane and the alkoxysilane which thus imparts a durable antistaticity, moisture absorbability and perspiration absorbability, resistance to soiling, rebound elasticity, flexibility, smoothness, creaseproofness and compression recovery. Said heating typically can be done at 130° to 160° C. for 3 to 10 minutes.
Examples of fiber materials which can be treated by the method of this invention are natural fibers such as wool, silk, hemp, cotton and asbestos; regenerated fibers such as rayon and acetate; synthetic fibers such as polyester, polyamide, vinylon, polyacrylonitrile, polyethylene, polypropylene and spandex; glass fiber; carbon fiber and silicon carbide fiber. The form of the fiber material includes staple, filament, tow, yarns, weaves, knits, nonwovens and resin-processed fabrics. Filament, tow, weaves, knits, nonwovens and Japanese mattress cotton can be effectively treated by continuous methods.
This invention will be explained, but not limited, using demonstrational examples. "Parts" in the examples denote "parts by weight" and the viscosity was measured at 25° C.
EXAMPLE 1
A hydroxyl group-terminated dimethylpolysiloxane (495 parts; viscosity, 90 cSt) was combined with the hydrolysis condensate (5 parts; viscosity, 530 cSt) of a silane with the formula CH 3 (CH 3 O) 2 Si(CH 2 ) 3 NHCH 2 CH 2 NH 2 and sodium hydroxide (100 ppm) as a catalyst. The resulting mixture was equilibrated at 90° C. for 10 hours and then neutralized with 150 ppm acetic acid to obtain a hydroxyl group-terminated, amino group-containing organopolysiloxane (viscosity, 3,750 cSt) serving as a component (a) of the compositions of this invention.
This component (a) (30 parts) was emulsified with polyoxyethylene nonylphenol ether surfactant (5 parts), a cationic surfactant (1 part) with the formula (CH 3 ) 3 (C 12 H 25 )N 30 Cl - and water (64 parts) using an emulsifier device to obtain a homogeneous starting emulsion.
The above starting emulsion was combined with an alkoxysilane (5 parts) with the formula (CH 3 O) 3 Si(CH 2 ) 3 O(C 2 H 4 O) 15 H serving as a component (b) of the compositions of this invention which was then dissolved and dispersed to homogeneity. The emulsion was then diluted 10-fold with water to obtain a treatment composition of this invention.
A 65/35 polyester/cotton white broadcloth was immersed in the above treatment composition, removed from the composition, wrung out with a mangle roll to 1.5 wt. % applied organopolysiloxane, dried at 110° C. for 5 minutes and then heat-treated at 140° C. for 5 minutes in order to conduct the crosslinking reaction between the amino group-containing organopolysiloxane and the alkoxysilane.
For comparison examples, broadcloth was treated with an emulsion of only the amino group-containing organopolysiloxane used in this example or with an aqueous solution of only the alkoxysilane under the same conditions as above.
The resistance to washing, antistaticity and hand of the above broadcloth were tested.
The washing treatment comprised two dry cleanings and two water washes. Dry cleaning consisted of washing the treated or untreated cloth with perchloroethylene under agitation for 15 minutes and then drying. The water wash consisted of washing the cloth in an automatic reversing electric washer on the "high" setting for 15 minutes using a 0.5% wt % aqueous solution of Marseilles soap, rinsing and then drying. The percent organopolysiloxane remaining on the washed fabric was measured using a fluorescence X-ray analyzer (from Rigaku Denki Kogyo Co., Ltd.).
The antistaticity was measured as follows. Treated or untreated cloth was allowed to stand overnight at 20° C. under a relative humidity of 65%. The cloth was then triboelectrified with a cotton cloth (unbleached muslin No. 3) using a Kyodai Kaken rotary static tester at 800 rpm for 60 seconds. The resulting triboelectric potential was measured.
The hand was inspected by the feel to the hand and was characterized as either excellent (appropriate smoothness, rebound elasticity and firmness so that the hand is extremely good), fair (poor smoothness and rebound elasticity so that the hand is not good) or poor (absence of smoothness and rebound elasticity so that the hand is extremely poor).
The results for each measurement are reported in Table I. The measured values demonstrate that, compared with the comparison examples, a cloth which had been treated by the method of this invention retained an excellent antistaticity and hand even after it had been dry cleaned and washed twice each.
TABLE I______________________________________ Samples Cloth Cloth treat- Cloth treated treated with ed with with aqueous fiber treat- Un- emulsion of solution of ment agent of treated only com- only com-Test Items this invention Cloth ponent (a) ponent (b)______________________________________Triboelectricpotential(volts)before 1450 1880 3830 1250washingafter washing 1590 1830 2480 1630Handbefore excellent poor excellent poorwashingafter washing excellent poor fair poor% Organo- 68 -- 22 8polysiloxaneremaining______________________________________
EXAMPLE 2
Octamethyltetrasiloxane (98parts) was combined with the hydrolysis condensate (1.5 parts; viscosity, 350 cSt) of an alkoxysilane with the formula
CH.sub.3 (CH.sub.3 O).sub.2 SiCH.sub.2 CH(CH.sub.3)CH.sub.2 NH.sub.2
and with an alkoxysilane (0.5 parts) with the formula (CH 3 O) 2 Si(CH 3 ) 2 and sodium hydroxide (70 ppm) as the catalyst. The resulting mixture was equilibrated at 105° C. for 10 hours and then neutralized with 100 ppm acetic acid to synthesize a methoxy group-terminated, amino group-containing organopolysiloxane (950 cSt) with the following general formula to serve as a component (a) of the compositions of this invention. ##STR4##
This component (a) (30 parts) was emulsified with a polyoxyalkylene nonylphenol ether surfactant (5 parts) and water (65 parts) using an emulsifier device to obtain a homogeneous starting emulsion.
This starting emulsion was combined with an alkoxysilane (10 parts) with the formula (CH 3 O) 3 Si(CH 2 ) 3 O(C 2 H 4 O) 20 (C 3 H 6 O) 20 CH 3 as a component (b) of the composition of this invention and this was subsequently dissolved and dispersed to homogeneity. The resulting mixture was diluted 10-fold to prepare a treatment composition of this invention. A 100% cotton underwear knit was immersed in this treatment composition, wrung out with a mangle roll to 0.5% wt % adhered organopolysiloxane, dried at 110° C. for 10 minutes and then heat-treated at 140° C. for 5 minutes in order to conduct the crosslinking reaction between the amino group-containing organopolysiloxane and the alkoxysilane.
For comparison examples, 100% cotton underwear knits were treated with an emulsion of the amino group-containing organopolysiloxane alone or with an aqueous solution of the alkoxysilane alone under the same conditions as described above.
The treated cloth was spread on a flat table. One drop of water was placed on each spread-out cloth and the time in seconds for the absorption and disappearance of the water drop was measured to serve as a water absorption test. The hand and the percent residual organopolysiloxane were measured by the method described in Example 1. Washing was also conducted by the same method as above.
The results are reported in Table II. Cloth treated by the method of this invention retained an excellent water absorbability and hand even after it had been dry cleaned and washed twice each.
TABLE II______________________________________ Samples Cloth Cloth treat- Cloth treated treated with ed with with aqueous fiber treat- Un- emulsion of solution of ment agent of treated only com- only com-Test Items this invention Cloth ponent (a) ponent (b)______________________________________Waterabsorbability(seconds)before 0 0 ≧1200 0washingafter washing 0 0 420 0Handbefore excellent poor excellent poorwashingafter washing excellent poor fair poor% Organo- 63 -- 31 11polysiloxaneremaining______________________________________
EXAMPLE 3
An alkoxysilane (100 parts) with the formula ##STR5## was combined with water (10 parts) and sodium hydroxide (50 ppm). The resulting mixture was allowed to stand at 50° C. for 7 hours, neutralized with 60 ppm acetic acid and then heated at 120° C. under a pressure of 7 mmHg in order to remove volatile components. The product was analyzed using a nuclear magnetic resonance analyzer from Hitachi Seisakusho Co., Ltd., in order to determine the ethoxy group hydrolysis ratio (%) which was found to be 66.8%. The product was thus confirmed to be a partial hydrolysis condensate. This partial hydrolysis condensate (10 parts) was combined with 100 parts of the starting emulsion comprising a component (a) of compositions of this invention from Example 2, dissolved and dispersed to homogeneity and then diluted 5-fold with water. A Tetron spun fiber for machine sewing was immersed in the above treatment composition, wrung out by centrifugal dewatering to 4 wt % applied composition, dried overnight at room temperature and then heat-treated at 150° C. for 5 minutes. The sewability was examined using an industrial sewing machine. Thread snapping, stitch dropping and sticking due to static electricity and inadequate lubricity were not observed. The sewability was thus excellent. These properties were retained even after the thread, which had been reeled up and placed in a washing bag, had been washed with water by the method described in Example 1. | An aqueous emulsion comprising an aminoorgano-substituted organopolysiloxane fluid, a silane which bears a hydrophilic group, one or more surfactants and water are useful for treating fibers, such as thread, yard and textiles. When applied to a fiber and heated the composition undergoes a curing reaction and durably imparts desirable properties, such as excellent hand and moisture absorbability, to the fiber. | 2 |
This is a continuation of co-pending application Ser. No. 603,801 filed on Apr. 25, 1984 and now abandoned.
FIELD OF THE INVENTION
This invention relates to yieldable structures. More particularly, this invention relates to yieldable swing sign structures which recover automatically.
BACKGROUND OF THE INVENTION
On vehicle roadways, particularly in areas where roadways are covered with snow for a part of the year, a continuing problem is the damage and destruction of highway signs and delineators situated at the side of the road for the guidance and warning of passing motorists. Of necessity such signs and delineators must be in close proximity to the roadway so that they can be readily observed by passing motorists. Because of their proximity to the edge of the road they are subject to damage by weed mowers, snow plows and occasionaily by automobiles.
A specific example is where signs are located by narrow one-lane bridges along rural roads that have concrete railings or abutments on both sides. Highway department standards in some states require that one foot by three foot reflective markers be installed directly above these concrete abutments. Because various farm equipment is wider than the space between these markers, the markers many times are knocked down whenever the equipment goes over the bridges. Also, snow plows blast heavy snow against these markers causing the markers to become so bent or twisted that they are no longer readable by approaching motorists. In some areas as many as 15 percent of all rural signs require repair each spring because of the damage inflicted during the winter.
These problems have been around for many years and because of the expense of procuring, installing and replacing roadway markers, the need to solve these problems is great. The prior art teaches various solutions to these problems but because of various reasons, i.e., too costly, poor maintenance and impracticality, they have not been widely accepted.
SUMMARY OF THE INVENTION
In accordance with the present invention, a new and improved yieldable structure is described.
The yieldable structure comprises a yieldable member and a support member for supporting the yieldable member. The support member is substantially parallel to the yieldable member. The yieldable structure has a pivoting mechanism fixed to the support member and the yieldable member for pivoting the yieldable member. The pivoting mechanism has a pivotal axis about which the yieldable member pivots. The yieldable structure also has a positioning mechanism for positioning the yieldable member in a selected position in relationship to the support member. The yieldable structure has a pivot limiting mechanism for limiting the displacement of the yieldable member from the selected position in relationship to the support member. The yieldable structure has a torsion mechanism which coacts with the support member and the yieldable member for providing a force to resist displacement of the yieldable member from the selected position. The torsion mechanism coacts axially through the pivotal axis of the pivoting mechanism. A first portion of the torsion mechanism is substantially parallel to the yieldable member and the support member.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawing:
FIG. 1 is an illustration of a highway sign in accordance with the present invention.
FIG. 2 is a detail of the highway sign illustrated in FIG. 1.
FIG. 3 is a cross section representation of the pivoting mechanism showing the torsion bar in accordance with the present invention.
FIGS. 4a, 4b, 4c and 4d are representations of the pivoting mechanism illustrated in FIGS. 1, 2 and 3 in accordance with the present invention.
FIG. 5 is a planar view of the yieldable member and the support member in the selected position in accordance with the present invention.
FIG. 6 is a planar view of the yieldable member displaced to the limit of its rotation about the pivoting mechanism in accordance with the present invention.
FIG. 7 is an illustration of a second embodiment of a highway sign in accordance with the present invention.
FIG. 8 is an illustration of a third embodiment of a highway sign in accordance with the present invention.
FIG. 9 is an illustration of a horizontal sign in accordance with the present invention.
FIGS. 10a and 10b illustrate a swing gate in accordance with the present invention with detail shown in FIG. 10b.
For a better understanding of the present invention, together with other and further objects, advantages and capabilities thereof, reference is made to the following disclosure and appended claims in connection with the above-described drawing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1 is an illustration of a yieldable structure 10 employed for supporting a highway sign. The structure 10 comprises a yieldable member 20 and a support member 30 for supporting the yieldable member 20. The yieldable member 20 is a frame with a highway sign 40 attached. The support member 30 is substantially vertical and elongated and the yieldable member 20 is substantially parallel to the support member 30. The structure 10 has two pivoting mechanisms 50. The pivoting mechanism 50 has two parts, a first "L" shaped portion 51 having a first opening 84 and a second "L" shaped portion 52 having a second opening 85 shown in FIGS. 2, 3, 4c and 4d. The first "L" shaped portion 51 is fixed to the yieldable member 20 and coacts with the second "L" shaped portion 52. The second "L" shaped portion 52 is fixed to the support member 30 and coacts with the first "L" shaped portion 51 as shown in FIGS. 2 and 3. The combination of the first "L" shaped pivot member 51 coacting with the second "L" shaped pivot member 52 comprise the pivoting mechanism 50. The pivoting mechanism 50 has a pivotal axis 60 shown in FIG. 3. The first "L" shaped pivot member 51 and the second "L" shaped portion 52 shown in FIG. 3 have the same pivotal axis 60 as the pivoting mechanism 50.
The first "L" shaped pivot member 51 and the second "L" shaped pivot member 52 have bearings 63 and 64 through which a torsion bar 70 passes as illustrated in FIG. 3. The torsion bar 70 acts like a hinge pin for the pivot mechanism 50 as well as resisting a radial displacement of the yieldable member 20 and resisting an axial displacement of the yieldable member 20 in relation to the support member 30. The first "L" shaped pivot member 51 and the second "L" shaped member 52 have positioning notches 54, 55, 56 and 57 shown in FIG. 3. FIGS. 4a, 4b and 4c illustrate the positioning notches 54 and 56 of the first "L" shaped pivot member 51. The first "L" shaped pivot member 51 shown in FIG. 4c is the same as the second "L" shaped pivot member 52 illustrated in FIG. 4d. The notches 54, 55, 56 and 57 all are made to impose an angle α of 40° from the horizontal plane of the pivot members 51 and 52. Shown in FIG. 4b are the notches 54 and 56 illustrating the 40° angle. The coacting of notches 54 and 56 with notches 55 and 57 respectively determine a selected position which the yieldable member 20 has with respect to the support member 30, illustrated in FIG. 5. Whenever a force, having a horizontal vector great enough, is applied to the yieldable member 20, the notches 54 and 56 lift out of notches 55 and 57 respectively shown in FIG. 3 by sliding along an inclined plane having the 40° angle α shown in FIG. 4b. Once the notches 54 and 56 are lifted out of notches 55 and 57 the yieldable member 20 is free to be displaced carrying the highway sign 40 attached thereto in an arc pivoting about the torsion bar 70 which passes through the pivotal axis 60 of the pivot mechanism 50 shown in FIG. 3. The torsion bar 70 resists the displacement force with a torsion force of its own. The torsion force increases the greater the displacement distance from the original selected position. The yieldable member 20 can be displaced through an arc up to but not exceeding a pre-determined position, such as 90°, from the selected position if sufficient force is applied. Rotation limiting mechanism 58 and 59, shown in FIG. 5 and 6, limit the displacement of the yieldable member 20. One of the rotation limiting mechanisms 58 located on one side of the first "L" shaped pivot member 51 coacts with one of the rotation limiting mechanisms 59 located on the inside face of the second "L" shaped pivot member 52 when the yieldable member 20 traverses an arc of 90° from the selection position; thereby, preventing the yieldable member 20 from proceeding past the 90° position in respect to its original selected position. Once the force which displaced the yieldable member 20 has been removed or reduced sufficiently for the resisting torsion force of the torsion bar 70 to overcome the displacement force the yieldable member 20 will be returned to its original selected position by the resisting torsion force of the torsion bar 70. The resisting torsion force decreases as the yieldable member 20 comes closer to its original selected position and reduces to zero once the yieldable member 20 reaches the selected position.
The pivoting mechanism 50 may have shear pin apertures 80 and 81 located in the first "L" shaped pivot member 51 and shear pin apertures 82 and 83 located in the second "L" shaped pivot member 52 to provide an alternative means for increasing the resistance to initial displacement of the yieldable member 20. This is accomplished by placing shear pins in the apertures 80 and 81 aligned with apertures 82 and 83. Shear pins of different shear forces can be utilized to permit design variations.
The torsion bar 70 has a first portion 71 which is substantially parallel to the support member 30 and the yieldable member 20 as illustrated in FIG. 2. The torsion bar 70 has a second portion 72 and a third portion 73, shown in FIG. 2, which are substantially perpendicular to the first portion 71, the yieldable member 20 and the support member 30. This configuration imparts a general "S" shape to the torsion bar 70. The second portion 72 coacts with the support member 30 and the third portion 73 coacts with the yieldable member 20 shown in FIG. 2 so whenever the yieldable member 20 is displaced from the selected position a torque is created in the torsion bar 70 which provides the torsion force to resist the displacement of the yieldable member 20. The general "S" shape of the torsion bar 70 also resists any axial displacement of the yieldable member 20 from the support member 30 by the coacting of the second portion 72 with the support member 30 and the coacting of the third portion 73 with the yieldable member 20. The resistance to an axial displacement helps maintain the engagement of notches 54 and 56 with corresponding notches 55 and 57. The length of torsion bar 70 can be changed to increase or decrease the torque required depending upon the design, the size, and weight of the yieldable member 20. As shown in FIG. 7 and 8, different highway signs may require more than one torsion bar. Shown in FIG. 7 is a second embodiment of a yieldable structure 12 having a support member 32, a yieldable member 22, two torsion mechanisms 72, two pivoting mechanisms 102 and a highway sign 42. Shown in FIG. 8 is a third embodiment of a yieldable structure 11, having a support member 31, a yieldable member 21, three torsion mechanisms 71, three pivoting mechanisms 101 and a highway sign 41. By changing the number of torsion bars and, or the length of the bars, a great variety of designs and variables may be incorporated into the same basic support member, yieldable member and pivoting mechanisms.
In accordance with the invention the yieldable structure can also be used to make horizontally supported signs as shown in FIG. 9. Illustrated in FIG. 9 is a horizontal structure 13 having a horizontal support member 33, a horizontal yieldable member 23, two torsion mechanisms 73, two pivoting mechanisms 103 and a sign 43. It can also be used to make yieldable mail box supports, yieldable display signs, swing gates, or any application where a supported frame is displaced in an arc about a vertical or horizontal support member by a force having a horizontal vector. FIG. 10a illustrates an example of how the instant invention can be used to make a swing gate 14 having a support member 34, a yieldable member 24, a torsion mechanism 74 and a pivoting mechanism 104 as shown in FIG. 10b.
While there has been shown and described what is at present considered the preferred embodiment of the invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined by the appended claims. | A yieldable highway swing sign is described which swings out of the way when struck by farm equipment or other objects such as wet snow from snow plows. The sign has a torsion bar which returns the sign to its original position after being struck. The sign has notches in its hinges to maintain its original position. The notches resist any displacement forces by providing an inclined plane of 40° which must be overcome before the sign is displaced in an arc pivoting around the torsion bar. The displacement of the sign is limited to a 90° displacement from the original position by the configuration of the hinges and is helped by the increased torque created by the torsion bar as the sign swings further from its original position. | 4 |
BACKGROUND OF THE INVENTION
As conducive to an understanding of the invention, it is noted that in known tension control devices, the carriages supporting the bearings of a deflecting roller are moved by means of spindles or chains, there being provided, for the purpose of maintaining uniform tension, a connecting shaft reaching from the "leader" side to the "drive" side of the paper handling machine, assuring synchrony of the carriages without travel-length difference. In order to effect a correction of so-called "off" belts or screens so that the distribution of tension becomes linear over the entire width of the belt or screen, it is also known to equip the connecting shaft with a mechanical clutch so that, for instance, by unplugging a pin, the connection is temporarily interrupted in order to achieve a carriage movement differing in distance traveled on the "leader" side and the "drive" side. The thus established uniform belt or screen tension is kept up by means of the re-engaged connecting shaft.
In order to be able to correct the runoff of the belt or screen edges, it is known to provide a pivotably mounted guide roller whose bearings are adjusted more or less as a function of the correct running of the edges, such as through pneumatic control devices. It is not possible with such known belt or screen runoff controls to influence the belt or screen tension so that, in addition to the control devices for the correct running of the edges, separate tension control devices are always required in known paper handling machines.
BRIEF SUMMARY OF THE INVENTION
It is an object of the invention to provide a mechanism for the control of the tension of an endless belt or screen for paper handling machines which permits permanent correction of deviations of the belt or screen circulation from the correct running of the edges without the need for an additional guide roller.
Starting from a tension control device for an endless belt or screen as described at the outset, the invention suggests, in order to solve the problem posed, than an adjustment device with a motor be provided for each carriage, the motors to have one common monitoring and control unit by means of which the carriages are adjustable selectively with or without travel-length difference.
The mechanism according to the invention obviates not only a connecting shaft to synchronize the carriages for belt or screen tension, but also a pivotably mounted guide roller to correct a belt or screen circulation deviating from the correct running of the edges, because the electronic monitoring and control unit provided for the two motors jointly makes it possible to adjust the deflecting roller parallel for tension control and to pivot it for run-off control.
According to one embodiment of the invention, the mechanism may comprise means for picking up the run-off of the belt or screen edges, these means being able to release pulses for a correcting carriage stroke.
Whereas, in the known devices for linear tension distribution, synchronization of the carriages for the deflecting roller bearings is accomplished by a connecting shaft and a separate, pivotably mounted guide roller serving the specific purpose of run-off control, the mechanism according to the invention makes it possible not only to generate pulses for the synchronization of the carriages for belt or screen tension control, but, in addition, to release run-off control pulses effecting a corrective bearing carriage stroke, pivoting the deflecting roller and thus assuming the function of the known guide roller.
Finally, according to another embodiment, the invention also suggests that the electronic monitoring and control unit contain a motor actuated set-point transmitter.
The design according to the invention makes it possible to preset difference set-points corresponding to a closed control loop, the motor actuated set-point transmitter providing the possibility of pre-setting the set-point for a difference adjustment as required to keep the edges of the belt or screen in certain positions or to return them constantly to these positions.
Position indicators, preferably of the contactless type known per se, triggering an appropriate corrective bearing carriage stroke depending on the deviations from the correct edge positions, may be used for the continuous determination of the edge positions.
Accordingly, the mechanism according to the invention eliminates a separate belt or screen run-off control including the mechanical part required therefor. Due to the fact that this also eliminates the space problems relating to the accommodation of a separate belt run-off control, the belts or screens can be kept considerably shorter without losing effectiveness.
BRIEF DESCRIPTION OF THE DRAWING
In the accompanying drawing in which is shown one of various possible embodiments of the various features of the invention, the single FIGURE is a schematic representation of the system.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, the depicted portion of an endless belt 1 is led across deflecting rollers 2, 3, 4 and 5, a magneto-elastic force recorder 6 to pick up the belt tension being associated with the deflecting roller 3. An edge scanning device 7 is disposed in the area of the deflecting roller 4 for the determination of the prevailing belt running position.
The journals of the deflecting roller 5 (not shown in the drawing), turn in bearings (also not shown) which are movable by means of carriages, covered up by housing 8, through spindless driven by three-phase gear motors 9. End position limit switches 10 limit the movement of the carriages and thus also the displacement of the deflecting roller 5.
The magneto-elastic force recorder 6 is connected to a bridge 11 wired to a double measuring amplifier 12 which serves the purpose of indicating the belt tension and for setting the actual value for the control loop. A moving coil tensiometer 13 connected to the double measuring amplifier 12 indicates the belt tension in kp/cm.
Another double measuring amplifier 14, again associated with a moving coil tensiometer 15 to indicate the travel-length difference between the so-called "leader" and "drive" side serves the purpose of indicating the travel-length difference between the "leader" and "drive" side and indicating the actual value for the bearing control loop.
The double measuring amplifier 14 is connected to a motor potentiometer 16, a superposed set-point tending to keep the belt edge in a defined position.
A set-point transmitter 17 serves the preselection of the desired belt tension and is connected to a three point control 18 with contactless output. The three point control 18 influences an electronic logic circuit 19 for the required electric wiring between belt run-off control and belt tension. Connected to the logic circuit 19 is a thyristor output stage 20 for reverse operation for the purpose of feeding the three-phase gear motor 9 of the "leader" side. In addition, there is connected to the logic circuit 19 a thyristor output stage 20 for reverse operation for the purpose of feeding the three-phase gear motor 9 on the "leader" side. In addition, there is connected to the logic circuit 19 a thyrister output stage 21 for reverse operation for the purpose of feeding the three-phase gear motor 9 on the "drive" side.
Another three point control 22 with contactless output serves the purpose of superimposing an additional correction component required due to the belt run-off control.
The belt edge scanner 7 is connected to an electronic logic circuit 23 succeeded by an amplifier 24 to feed the motor actuated difference set-point transmitter from the motor potentiometer 16.
The logic circuit 25 takes care of the synchronization between "leader" and "drive" side, analog displacement transducers being provided on both sides.
MODE OF OPERATION OF THE INVENTION
The operating mode of the mechanism is as follows:
Before the circulating of the belt 1 is started, it receives a minimum tension so that a destruction of the belt 1 due to the formation of folds can be avoided and a run-off correction made possible right from the start. The minimum tension of the belt 1 is controlled in that the prevailing belt tension is picked up by the magneto-elastic force recorder 6 via the associated bridge 11 and the measuring amplifier 12 and caused to be displayed by the moving coil tensiometer 13.
When the minimum belt tension is reached, the belt run-off control is started. For instance, if the "leader" side of the belt 1 is to advance by a certain amount relative to the "drive" side so as to assure proper running of the edges, the electronic logic circuit 22, receiving its information via the analog displacement transducer 26 succeeded by the double measuring amplifier 14 with consideration of the motor potentiometer 16, sees to it that the continuous motion of the leading side is interrupted until synchrony is reestablished. This means in the assumed example that the three-phase gear motor 9 drive system on the "drive" side is stopped until, taking into account the difference set-point, the "leader" side has attained the desired position relative to the "drive" side. For the relief operation, assuming the same mutual relationship, this would mean that it would not be the three-phase gear motor 9 on the "drive" side, but the corresponding motor 9 on the "leader" side which would have to remain stopped, because, when relieving, it is the "leader" side which is leading relative to the "drive" side.
If, after the attainment of the desired belt tension, the belt edge runs off due to the effect of whatever interference, the magnitude of the rquired difference between the "leader" and the "drive" side will be determined by the electronic logic circuit 23 and given to the motor potentiometer 16 via the measuring amplifier 24. The three point control 25 with contactless output then initiates an appropriate correction on the 37 drive" side which is located in back in the drawing. | The invention relates to a device for the control of the tension of an endless belt or screen in paper handling machinery by providing a deflecting roller displaceable by two bearings guided in carriages. | 3 |
RELATED APPLICATIONS
[0001] The present application is a Continuation of co-pending PCT Application No. PCT/ES02/00041, filed Jan. 30, 2002 which in turn, claims priority from Spanish Application Serial No. 200100268, filed on Jan. 30, 2001. Applicants claim the benefits of 35 U.S.C. §120 as to the PCT application and priority under 35 U.S.C. §119 as to said Spanish application, and the entire disclosures of both applications are incorporated herein in their entireties.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention belongs to the sector of microporous zeolitic materials, particularly to synthetic laminar zeolitic materials and more specifically to catalysts corresponding to such materials.
[0003] 1. Objects of the Invention
[0004] The first object of the present invention is a microporous crystalline material with laminar characteristics useful as a catalyst in the dewaxing and isodewaxing of paraffins and toluene disproportionation.
[0005] A second object of the invention is a method for the preparation of the microporous zeolitic material and the most suitable conditions for synthesis thereof in order to obtain a product that can be used as an adsorbent and catalyst in processes in which organic molecules take part.
[0006] A third object of the invention is the use of the above-cited material, in catalytic conversion processes of organic compounds as a catalyst in catalytic conversion processes of organic compounds, such as dewaxing and isodewaxing of paraffins and toluene disproportionation.
[0007] 2. Prior Art
[0008] Natural as well as synthetic zeolitic materials have very interesting catalytic properties for various types of conversion of hydrocarbonaceous compounds. These materials have a defined structure, that is determined by X-ray diffraction, having a large number of small cavities which may be interconnected by even smaller channels or pores. These cavities and pores are uniform and repetitive within each one of the zeolitic materials. Due to the molecular dimension of these pores molecules of a certain size can be adsorbed and other larger ones can be rejected. These materials are known as “molecular sieves” and are used in a multitude of uses that employ this characteristic as an advantage.
[0009] Such molecular sieves include a wide variety of crystalline silicates which are described as rigid three-dimensional framework formed by tetrahedrons of SiO 4 or of any other T +4 metal. There is the possibility of introducing acidity upon replacing in the lattice of the molecular sieve, some T +4 cations by T +3 cations, such as aluminum, which give rise to a structural charge deficiency that may be compensated for by protons, Bronsted acidity, and/or high charge-radius ratio cations, Lewis acidity. These compensation cations may be totally or partially exchanged by another type of cation using conventional exchange techniques. Hence, it is possible to vary the properties of a silicate specifically according to the chosen cation. This type of microporous material is used as selective adsorbents and/or catalysts in petrochemical and refining processes, as well as fine chemistry.
DESCRIPTION OF THE INVENTION
[0010] The present invention refers to a microporous material of zeolitic nature (also known as ITQ-19 in the present specification), that has a composition, in an anhydrous and calcinated state, in accordance with the empirical formula
x (M 1/n XO 2 ): y YO 2 :(1 −y )SiO 2
[0011] wherein
[0012] x has a value less than 0.2, preferably less than 0.1, and more preferably less than 0.02, and it may have the value 0;
[0013] y has a value less than 0.1, preferably less than 0.05, and more preferably less than 0.02; and it may have the value 0.
[0014] M is at least one +n charge inorganic cation and may be H;
[0015] X is at least one chemical element with a +3 oxidation state, preferably selected among Al, Ga, B, Cr, Fe;
[0016] Y is at least one chemical element with a +4 oxidation state, preferably selected among Ge, Ti, Sn, V.
[0017] In a calcinated state at 540° C., the material of the invention has an X-ray diffraction pattern with the basal spacings and relative intensities indicated in Table 1.
TABLE 1 d(Å) (I/IO) * 100 d(Å) (I/IO) * 100 11.95 ± 0.02 w 3.82 ± 0.05 m 9.19 ± 0.03 vs 3.69 ± 0.03 w 6.85 ± 0.01 s 3.46 ± 0.07 s 6.12 ± 0.05 w 3.32 ± 0.06 m 5.53 ± 0.03 w 3.25 ± 0.08 w 4.86 ± 0.06 w 3.07 ± 0.03 w 4.73 ± 0.04 w 2.98 ± 0.04 w 4.60 ± 0.02 w 2.88 ± 0.05 w 4.48 ± 0.05 w 2.82 ± 0.06 w 4.35 ± 0.04 w 2.66 ± 0.07 w 4.23 ± 0.02 w 2.56 ± 0.05 w 4.11 ± 0.03 w 2.43 ± 0.09 w 3.89 ± 0.04 m 2.35 ± 0.08 w
[0018] This material has a microporous structure and a high thermal stability; it can have Bronsted and Lewis acid centers and can be prepared in the purely siliceous form.
[0019] Preferably, the Si/X ratio is from 30 to 400.
[0020] This material may be obtained by calcinating a precursor (also known as PREITQ-19 in the present specification), which precursor has, in a dry state, an X-ray diffraction pattern according to the basal spacings and relative intensities indicated in Table 2.
TABLE 2 d(Å) (I/IO) * 100 d(Å) (I/IO) * 100 11.22 ± 0.02 vs 3.60 ± 0.08 s 10.10 ± 0.03 w 3.52 ± 0.05 vs 8.81 ± 0.05 w 3.42 ± 0.06 s 7.05 ± 0.01 w 3.36 ± 0.04 s 6.30 ± 0.01 m 3.32 ± 0.05 w 5.60 ± 0.02 w 3.30 ± 0.01 w 5.28 ± 0.05 s 3.14 ± 0.07 w 4.98 ± 0.06 s 3.10 ± 0.02 w 4.72 ± 0.01 w 3.09 ± 0.03 w 4.38 ± 0.02 s 3.01 ± 0.01 w 4.21 ± 0.02 s 2.81 ± 0.04 w 3.90 ± 0.03 w 2.61 ± 0.04 w 3.83 ± 0.08 m 2.51 ± 0.05 w 3.73 ± 0.07 a 2.48 ± 0.09 w
[0021] On the other hand, the precursor PREITQ-19, since it is calcinated at temperatures higher than 300° C., collapses and gives rise to the three-dimensional structure of ITQ-19.
[0022] In an embodiment of the material ITQ-19, the material has a composition, in anhydrous and calcinated state, of the empirical formula
x (M 1/n XO 2 ): y YO 2 :(1 −y )SiO 2
[0023] wherein
[0024] x has a value of 0.0025 to 0.035;
[0025] M is at least one inorganic cation with an n valence, and it can be, for example Li,
[0026] X is Al, and
[0027] y is zero.
[0028] The embodiment of the material ITQ-19 corresponding to this empirical formula, in turn corresponds to the following formula expressed in terms of moles of oxide per mol of silica,
(0.05)M 2 /n O: (0−0.0335)Al 2 O 3 :SiO 2
[0029] wherein M is at least one inorganic cation with an n valence.
[0030] In accordance with the invention the inorganic cation M conveniently has a compensation cation function and can be selected at least partially from among hydrogen and alkaline metals like Li, Na and K.
[0031] The present invention also refers to a process for preparation of the material ITQ-19. Such process comprises the following stages:
[0032] A precursor is prepared in a first step by subjecting to heating, with or without stirring, at a temperature between 100 and 225° C., preferably between 125 and 200° C., a reaction mixture that contains water and
[0033] a SiO 2 source, that preferably has, in order to enhance the formation of the final material ITQ-19 without the presence of liquid phases considered as impurities, at least 30% of solid silica, such as for example AEROSIL, LUDOX, ULTRASIL, HISIL or tetraethylorthosilicate (TEOS),
[0034] optionally a source of at least another tetravalent element Y preferably selected among Ge, Ti, V, Sn,
[0035] optionally a source of at least another trivalent element X preferably selected among Al, B, Ga, Fe, Cr,
[0036] an organic cation 1-methyl-1,4-diazabicyclo[2,2,2] octane as a structure directing agent, and
[0037] optionally an inorganic cation, preferably a source of alkaline metal such as for example an oxide, hydroxide or salt of lithium, sodium or potassium,
[0038] until crystallization of the reaction mixture is achieved.
[0039] The reaction mixture has a composition, in terms of molar ratios of oxides, comprised between the ranges:
[0040] ROH/SiO 2 =0.01-1.0, preferably 0.1-1.0,
[0041] M 1/n OH/SiO 2 =0-1.0, preferably 0-0.2,
[0042] X 2 O 3 /SiO2=0-0.1, preferably 0-0.05, and more preferably 0-0.01,
[0043] YO 2 /(YO 2 +Sio 2 ) less than 1, preferably less than 0.1,
[0044] H 2 O/SiO 2 =0-100, preferably 1-50,
[0045] wherein
[0046] M is at least a +n charge inorganic cation;
[0047] X is at least a trivalent element preferably selected among Al, B, Ga. Fe and Cr;
[0048] Y is at least a trivalent element preferably selected among Ge, Ti, Sn, V;
[0049] R is an organic cation, preferably 1-methyl-1,4-diazabicyclo[2,2,2]octane (DABCO), which may be added in hydroxide form and another salt to the reaction mixture.
[0050] The definition of the reaction mixture based on its empirical formula is the following:
r ROH: a M 1/n OH: x X 2 O 3 :y YO 2 :(1 −y )SiO 2 :z H 2 O
[0051] wherein M, X and Y have the above-cited meanings and wherein
[0052] r=0.01-1.0, preferably 0.1-1.0
[0053] a=0-1.0, preferably 0-0.2
[0054] x=0-0.1, preferably 0-0.5, and more preferably 0-0.01
[0055] y is less than 1, preferably less than 0.1
[0056] z=0-100, preferably 1-50.
[0057] The reaction mixture preferably has a composition, in terms of molar ratios of oxides, comprised among the ranges
[0058] SiO 2 /Al 2 O 3 =15,199, preferably 50-199,
[0059] H 2 O/SiO 2 =10-200, preferably 20-100,
[0060] OH − /SiO 2 =0.01-2, preferably 0.1-1,
[0061] R/SiO 2 =0.02-1, preferably 0.05-0.75,
[0062] M/SiO 2 =0.01-3, preferably 0.05-2,
[0063] wherein
[0064] M is at least a +n charge inorganic cation;
[0065] R is an organic cation, preferably 1-methyl-1,4-diazabicyclo[2,2,2]octane (DABCO), in the form of hydroxide and another salt can be added to the reaction mixture.
[0066] In one embodiment, the reaction mixture is, in terms of moles of oxide per mole of silica, the following:
(0.1-1)ROH:0-0.05)M 1/n OH:0.0025-0.335)Al 2 O 3 :SiO 2 :z H 2 O
[0067] wherein
[0068] M has the above-cited meaning,
[0069] R is an organic cation that acts as a structure directing agent, and
[0070] z is a value of 0 to 100, preferably 1-50.
[0071] In accordance with the above, the precursor PREITQ-19, upon being calcinated at temperatures higher than 300° C., collapses and gives rise to the three-dimensional structure of the ITQ-19.
[0072] Adding the trivalent element or elements and/or tetravalent elements can be done prior to the heating of the reaction mixture or in a intermediate phase during heating.
[0073] Optionally, an amount of crystalline material, preferably with the characteristics of the material ITQ-19, as crystallization promoter, can be added to the reaction mixture. The amount of this promoter material is comprised between 0.01 to 15%, preferably 0.05 to 5% by weight referred to the total amount of silica added.
[0074] The first step normally has a duration of between 1 and 30 days, preferably 2 to 15 days and it normally proves to be a white solid.
[0075] Then in a second step the precursor is washed, preferably with distilled water, filtered, dried and subjected to calcination. Such calcination can be carried out in an air flow, at a temperature between 300° C. and 800° C., preferably between 400 and 600° C. for at least 3 hours.
BRIEF DESCRIPTION OF THE DRAWINGS
[0076] As an integral part of the present specification, some drawings are attached hereto, wherein
[0077] [0077]FIG. 1 is a diffractogram of a typical sample of the material ITQ-19, and
[0078] [0078]FIG. 2 is a diffractogram of a typical precursor PREITQ-19 as a precursor of the material ITQ-19.
EMBODIMENTS OF THE INVENTION
[0079] Some examples of the embodiment of the invention will be described hereinafter.
EXAMPLES
Example 1
[0080] A purely siliceous laminar precursor PREITQ-19 is described in this first example. The synthesis gel was prepared using: lithium hydroxide (Fisher), monomethylated 1-methyl-1,4-diazabicyclo[2,2,2]octane hydroxide (DABCO) and an aqueous silica solution (30% by weight) (HS-30 Dupont, Aldrich.).
[0081] 0.175 g. LiOH.H 2 O, 108.18 g. DABCO-Me-OH (0.5 M) and 16.667 g. SiO 2 (30% by weight) are mixed and stirred vigorously in a thermostatic bath at 50° C. until the 52.1521 g. of water present in the mixture evaporate. Hence, we obtain a synthesis gel, with a pH close to 13, with the following molar composition:
[0082] 0.05 LiOH:0.65 R—OH:0.01 SiO 2 :40 H 2 O (R=Methylated DABCO).
[0083] Afterwards, the gel is introduced in stainless steel autoclaves with TEFLON covers and left for 7 days at 175° C. with a stirring speed of 60 rpm.
[0084] After this treatment, the samples are filtered and washed with distilled water until the pH of the washing water is <9. Drying is done afterwards in order to obtain the laminar precursor PREITQ-19, whose X-ray diffractogram coincides with the one of FIG. 2, with relative intensities and basal spacings coinciding with those shown on table 2.
Example 2
[0085] A portion of the laminar precursor PREITQ-19 obtained in example 1 is calcinated at 540° C. for three hours in an air flow, obtaining the collapsed material with a three-dimensional structure named ITQ-19 that has an X-ray diffractogram that is shown in FIG. 1 with relative intensities and basal spacings coinciding with those shown in table 1.
Example 3
[0086] [0086] 0 . 175 g. of LiOH. H 2 O, 41.6 g. of DABCO-Me-OH (0.5 M), 9.620 g. of milli-Q H 2 O and 16.667 g. of SiO 2 (30% by weight are mixed and stirred vigorously for 1 hour at room temperature, obtaining a gel that has a pH of 12.60. This synthesis gel has the following molar composition:
[0087] 0.05 LiOH:0.25 R—OH:1 SiO 2 :40 H 2 O (R=Methylated DABCO).
[0088] Afterwards, the gel is introduced in stainless steel autoclaves with TEFLON covers and left for 12 days at 1750° C. with a stirring speed of 60 rpm.
[0089] After this treatment, the samples are filtered and washed with distilled water until the pH of the washing water is <9. Drying at 60° C. is done afterwards in order to obtain the laminar precursor PREITQ-19, whose X-ray diffractogram coincides with the one of FIG. 2, with relative intensities and basal spacings coinciding with those shown on table 2.
Example 4
[0090] When we calcine the material PREITQ-19 obtained in example 3, for 5 hours at a temperature of 540° C., the zeolitic material ITQ-19 claimed in this patent is obtained, its X-ray diffractogram basically coinciding with the one of FIG. 1, with relative intensities and basal spacings coinciding with the ones shown on table 1.
Example 5
[0091] This example describes the preparation of the laminar precursor PREITQ-19. The synthesis gel was prepared by using lithium hydroxide (Fisher), alumina (pseudoboehmite, 73.7% by weight, Catapal B Vista), monomethylated DABCO hydroxide (1-methyl-1,4-diazabicyclo[2,2,2]octane) and an aqueous solution of silica (30% by weight) (HS-30 LUDOX, Aldrich).
[0092] 0.132 g. of LioH.H 2 O, 0.09 g. of Al 2 O 2 (73-7% by weight), 81.135 g. DABCO-Me-OH (0.5 M) and 12.501 g. of SiO 2 (30% by weight) are mixed and stirred vigorously in a thermostatic bath at 50° C. until the 39.141 g. of water present in the mixture evaporate. Thus, we achieve a synthesis gel with a pH close to 13, with the following molar composition:
[0093] 0.05 LIOH:0.65 R—OH:0.01 Al 2 O 3 :1 SiO 2 :40 H 2 O (R=Methylated DABCO).
[0094] Afterwards, the gel is introduced in stainless steel autoclaves with TEFLON covers and left for 7 days at 175° C. with a stirring speed of 60 rpm.
[0095] After this treatment, the samples are filtered and washed with distilled water until the pH of the washing water is <9. Drying is done afterwards in order to obtain the laminar precursor PREITQ-19, whose X-ray diffractogram coincides with the one of FIG. 2, with relative intensities and basal spacings coinciding with those shown on table 2.
Example 6
[0096] A portion of the laminar precursor PREITQ-19 obtained in example 5 is calcinated at 540° C. for three hours in an air flow, obtaining the collapsed material with a three-dimensional structure named ITQ-19 that has an X-ray diffractogram that is shown in FIG. 1 with relative intensities and basal spacings coinciding with those shown in table 1.
Example 7
[0097] [0097] 0 . 132 g. of LiOH.H 2 O, 0.09 g. of Al 2 O 2 (73.7% by weight), 41.6 g. DABCO-Me-OH (0.5 M) 9.620 g. of milli-Q H 2 O and 12,501 g. g. of SiO 2 (30% by weight) are mixed and stirred vigorously for 1 hour at room temperature, obtaining a synthesis gel with a pH close to 12.60. This synthesis gel has the following molar composition:
[0098] 0.05 LiOH:0.25 R—OH:0.01 Al 2 O 3 :1 SiO 2 :40 H 2 O (R=Methylated DABCO).
[0099] Afterwards, the gel is introduced in stainless steel autoclaves with TEFLON covers and left for 12 days at 175° C. with a stirring speed of 60 rpm.
[0100] After this treatment, the product is filtered and washed with distilled water until the pH of the washing water is <9. Drying at 60° C. is done afterwards in order to obtain the laminar precursor PREITQ-19, whose X-ray diffractogram coincides with the one of FIG. 2, with relative intensities and basal spacings coinciding with (similar to) those shown on table 2.
Example 8
[0101] When we calcine the material PREITQ-19 obtained in example 7, for 5 hours at a temperature of 540° C., the zeolitic material ITQ-19 claimed in this patent is obtained, its X-ray diffractogram basically coinciding with the one of FIG. 1, with relative intensities and basal spacings coinciding with the ones shown on table 1. | The invention relates to a novel microporous crystalline material ITQ-19 used in the catalytic conversion of organic compounds, such as, for example, the dewaxing and isodewaxing of paraffins and the disproportionation of toluene. Said material has a characteristic X-ray diffractogram, a high absorption capacity and the empirical formula x(M 1/n XO 2 ):yYO 2 :(1−y)SiO 2 wherein x has a value less than 0.2; y has a value less than 0.1; M is at least an inorganic cation with a +n charge; X is at least a chemical element having oxidation state +3, preferably selected among Al, Ga, B, Cr, Fe; Y is at least a chemical element with oxidation stated +4, preferably selected among Ge, Ti, Sn, V. The inventive material can be obtained by means of a preparation process involving the use of one or more organic additives in a reaction mix which is crystallized by heating. | 2 |
STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government for governmental purposes without the payment of any royalty thereon.
This application is a continuation of application Ser. No. 07/407,594, filed Sep. 15, 1989, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to treatment of carbon fibers and, in particular, to the treatment of the surface of carbon fibers in order to increase the active surface area, total surface area, and surface roughness of these fibers.
Carbon fibers because of their unique combination of properties are finding increased use in fields as diverse as energy, sporting goods and aerospace. Because of their relative chemical inertness, they are finding use as a catalyst support in fuel cells and in numerous other chemical reactions. In a structural composite the fiber properties that are most useful are their high strength, high modulus, and low density. At elevated temperatures these fibers become even more attractive in structural composites because they have very significant strength and modulus up to 3000° C. Thus, it is the matrix material and not the fiber that determines the composites useful temperature envelope. For applications up to about 300° C. the matrix is usually an epoxy or a phenolic, while at higher temperatures a metal matrix can be used. At temperatures above 1200° C. the matrix must be a ceramic or carbon itself. These carbon-carbon composites are very useful materials that have found wide application because they are stronger and stiffer than steel, have a lower density, and maintain their properties to very high temperatures.
Carbon fiber composites can be tailored to have a wide range of properties. Apart from using different carbon fibers this can be accomplished by modifying (1) the fiber architecture, (2) the matrix material, or (3) the degree of fiber-matrix bonding. It is possible to modify the fiber-matrix interface by changing the fiber's surface roughness, or the degree of chemical interaction between the fiber and the matrix.
The degree of chemical interaction between the fiber and the matrix, which is the most important of these three parameters, can be enhanced in order to increase the tensile strength of the composites. This results in a decreased failure rate due to fiber pull-out under tensile stress.
This enhancement in chemical bonding can be accomplished by increasing the fiber's active surface area (ASA) which is composed of all the sites on a carbon fiber surface capable of forming a chemical bond. These sites are located on the carbon surface wherever the valence is not satisfied. Typically, the majority of these sites are located at the edges of the basal planes but active sites are also located at any imperfection in the basal plane such as vacancies, dislocations, interstitials, etc.
It is the ASA that also acts as bonding sites for metal particles placed on the carbon fiber surface to serve as catalysts. Carbon fibers as a catalyst support find application in numerous chemical reactions such as in fuel cells, heterogeneous reactions, and as electrodes in electrochemical processes. Carbon fibers in these applications improve mechanical properties and give better thermal shock resistance. For this reason, it is desirable to significantly enhance the size and number of ASA patches on a carbon fiber surface used as a catalyst support. This ASA enhancement would increase both the amount of catalyst that could be placed on the surface and its degree of dispersion. Both of these parameters have a significant effect on the efficiency of the supported catalyst.
Further, the carbon active sites also serve as nucleation sites for any deposit or coating. In many cases, such as for oxidation protection, it is desirable to coat carbon fibers or composites made from them. To accomplish this it is necessary to have a significant number of ASA patches with a certain minimum size in order to bond coatings, which are composed of molecules much larger than an oxygen molecule, to the fiber surface.
Traditional manufacturing process to increase the number of carbon fiber active sites include oxidation in air, nitric acid, or an electrochemical cell. The limitation of all these techniques is that they only increase the size of ASA patches already present on the surface but are unable to create ASA patches in the perfect basal plane areas.
On the other hand, alternate techniques such as plasma etching in argon or oxidation in atomic oxygen, in addition to removing edge sites are able to remove basal plane atoms and create ASA patches where none existed previously. However, even these process are not as effective in increasing the fiber active surface area as catalytic oxidation. Some of these prior process are disclosed in the following U.S. Patents which are incorporated by reference:
______________________________________ 3,476,703 3,989,802 3.657,802 4,009,305 3,720,536 4,374,114 3,746,560 4,490,201______________________________________
SUMMARY OF THE INVENTION
The invention comprises a process to significantly increase both the active surface area and total surface area of carbon fibers with negligible weight-loss while at the same time creating active surface areas where none previously existed.
In order to increase both the active surface area and the total surface area, a metallic or metal oxide coating, capable of catalyzing carbon gasification, is, firstly, applied to the carbon fibers.
If the coating is applied from the liquid or solid phase, the fibers are then washed in distilled water and dried. The coated fibers are then heated from room temperature up to the gasification temperature in a reactive atmosphere at a rate that is less than 10° C./sec. The fibers are then gasified using oxygen, hydrogen, carbon dioxide or air to the desired level of weight-loss which is kept to a minimum. The fibers are then cooled to a room temperature. At this time the coating is removed and the fibers are ready for use.
In a preferred embodiment of the present invention the coating is metallic silver that has been deposited from solution. The silver coated fibers are heated from room temperature to about 500° C. at 20° C./min in flowing air and oxidized until the desired active surface area increase is obtained. However, if other metals are used the temperature might be higher. The metal coating is removed by means of a dissolving acid which is incapable of dissolving the carbon fiber.
It is therefore one object of the present invention to provide a process of increasing carbon fiber's total and active surface area in order to improve the degree of fiber-matrix bonding.
Another object of the present invention is to provide a process of increasing the fiber's total and active surface area in order to improve the degree of bonding between a carbon fiber composite and a coating.
Another object of the present invention is to provide a process of creating active sites in perfect basal plane regions so that fiber-matrix bonding can occur where none existed previously.
Another object of the present invention is to provide a process of creating active sites in perfect basal plane regions so that the amount of catalyst and its degree of dispersion on a carbon fiber surface can be increased.
Another object of the present invention is to provide a process of enlarging active surface area patches so that other matrix and coating materials not currently used because of insufficient bonding area can be employed in the manufacture of composites made from carbon fibers.
Another object of the present invention is to provide a process of increasing both active sites and surface area to enhance fiber-matrix bonding, mechanical properties of composites of such, and to increase the amount of catalyst loading and its dispersion when carbon fibers are used as a catalyst support.
These and many other objects and advantages of the present invention will be readily apparent to one skilled in the pertinent art from the following detailed description of a preferred embodiment of the invention and the related drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A, 1B, 1C and 1D schemately illustrate the results of different processes carbon removal types created by different means of oxidation of carbon fiber.
FIG. 2 illustrates the increase in the active surface area (ASA) by the present invention.
FIG. 3 illustrates the increase the in the total surface area by the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides a process to create new active sites on carbon fiber surfaces substantially increasing both the active and the total surface area of the carbon fiber with less than 1% weight-loss during the process. Weight-loss must be minimized so that the fiber's excellent mechanical properties are not degraded.
The active sites are created by catalytic gasification where a metal or metal oxide is used as a catalyst during the gasification of carbon. After gasification the metal or metal oxides may be removed and reclaimed. Any metal or metal oxide that forms pits or channels in the carbon surface during oxidation may be used. Channeling catalysts are preferred because pitting catalysts usually do not gasify as quickly and result in pits that can go through the fiber and degrade the mechanical properties. A solution to this problem is to use pitting catalysts during a mild gasification and then remove it. After this step, a channeling catalyst is deposited on the pitted surface and gasification is restarted. FIG. 1 illustrates the pitting and channeling in carbon fibers, and in particular, FIG. 1D, schematically illustrates that catalytic silver oxidation forms channels in a perfect basal plane region.
In general any metal or its oxide that forms pits or channels in the carbon fiber surface can be used to oxidize the carbon fiber surface. These metals would include the transition metal, its oxide, or combinations from the following list:
______________________________________platinum nickel iridiumrhenium vanadium leadtungsten palladium cobaltiron molybdenum coppercadmium chromium manganeseruthenium silver gold______________________________________
In reference to FIGS. 2 and 3, it is seen that silver, for example, used in the catalytic gasification, provided an almost three fold increase in the active surface area with only about 1% fiber burn-off.
The invention further provided approximately a 30% increase in the total surface area.
Silver may also be used for catalytic gasification of carbon fibers used in carbon-carbon composites because of the compensation effect. That is, above 1000° C. silver actually inhibits the oxidation of carbon. Thus, even if traces of silver remained on the surface, the silver would act as an inhibitor toward gasification at high temperature where these composites find application.
The metal or its oxide can be applied to the fiber surface from a solid, liquid or gaseous source such as deposition from solution, chemical vapor deposition, sputtering, electrodeposition, electrophoresis, sol-gel, pack cementation, or plasma deposition. Depending upon the process of deposition of the metal, or its oxide, the fiber surface may have to be cleaned prior to deposition. Once the metal or its oxide is on the surface, the fiber is heated in a reactive atmosphere at a rate less than 10° C./sec to a temperature at which the metal starts to move on the surface.
The temperature at which the metal commences movement, i.e. becomes mobile, and catalytic channeling or pitting starts is equal to about the half the bulk melting point of the metal. The catalytic gasification occurs at or above this temperature. In practice the temperature is held constant at or less than 200° C. above the temperature at which mobility commences. If the temperature is raised too high, the catalyst can lose its activity. Gasification is terminated when the desired weight-loss is reached. The sample is then cooled and the catalyst is removed. The most convenient way to remove the catalyst is by treatment in an acid solution, but any process that does not degrade the carbon fiber can be used. The metal can then be reclaimed from the acid solution if desired. Once the catalyst has been removed the sample is washed in distilled water and dried.
It has been determined that the initial metal loading on an untreated carbon fiber was low because of the small active surface area. As the silver channeled across the surface it was depleted and catalytic oxidation stopped. To restart the catalytic oxidation, it was necessary to recoat the carbon fibers with metal. The metal loading on the second cycle was substantially higher than on the first cycle. Thus, for some applications a second coating is necessary to either further increase the fiber active surface area by catalytic gasification or to coat the fiber for other applications such as a catalyst support for heterogeneous reactions as well as electrodes for fuel cells or other electrochemical cells.
Although the carbon can be removed by gasification as noted above, the carbon may be removed in an electrochemical cell being a liquid environment. The reactive environment may be a gaseous atmosphere or plasma such as oxygen, hydrogen, carbon dioxide or air.
After this step, the activated fibers can be made into a final product or can undergo further processing. An example of further processing would be additional activation by catalytic gasification or by using another technique, such as oxidation in air, atomic oxygen, nitric acid, an electrochemical cell, etc.
EXAMPLE
Unsized P-55 graphitized pitch fiber samples were subjected to various surface treatments. These included treatment in atomic oxygen and argon plasma using a Branson/PCS 3000 Plasma System as well as air oxidation of as-received and silver-coated samples at temperatures between 450° and 550° C. Although nitric acid worked well with an ungraphitized PAN (T-300) fiber, treatment of the graphitized fibers in nitric acid was not very sucessful and was not continued.
To place silver on the fiber surface, the sample was stirred in a silver diammine solution for 24 hours at room temperature. The sample was then washed in distilled water, dried, and oxidized in air in the temperature range between 450° C. and 550° C. Subsequent to the oxidation, the silver was removed in 1N nitric acid which was kept at 50° C. overnight. The sample was then washed in distilled water and dried.
After each surface treatment was completed, the active and total surface areas were measured. measured. The oxygen active surface area (ASA o2 ) was measured by oxygen chemisorption at 300° C. The total surface area was measured by krypton adsorption at -195° C.
From FIG. 2, it is apparent that all the surface treatments increased the oxygen active surface area of the fiber (from 0.0342/m 2 g) with only a 1.5% loss in weight. It is also evident that catalytic oxidation using silver was the most efficient technique. With this technique the ASA was augmented to a value twice as great as that obtained by the other process at the same weight loss.
The data presented in FIG. 3 show that catalytic silver oxidation was also the most efficient technique attempted to increase the total surface area of the fiber (from 0.458 m 2 /g) while keeping the weight loss less than 2%.
Clearly, many modifications and variations of the present invention are possible in light of the above teachings and it is therefore understood, that within the inventive scope of the inventive concept, the invention may be practiced otherwise than specifically claimed. | Carbon fibers having substantially increased active surface area and total surface area are used to enhance carbon fiber bonding to matrix materials in carbon fiber products. The enhanced active surface area and total surface area are produced by carbon removal in disordered regions as well as perfect basal plane regions by catalytic silver oxidation. | 3 |
BACKGROUND OF THE INVENTION
The present invention generally relates to circuit board components, and more particularly to processes for assembling and reflow soldering a double-sided circuit component to a pair of opposing substrates.
Various types of circuit board components have been specifically developed for high current and high power applications, such as hybrid and electric vehicles. Such components often comprise a semiconductor device, such as a diode, thyristor, MOSFET (metal oxide semiconductor field effect transistor), IGBT (isolated gate bipolar transistor), resistors, etc., depending on the particular circuit and use desired. Vertical devices are typically formed in a semiconductor (e.g., silicon) die having metallized electrodes on its opposite surfaces, e.g., a MOSFET or IGBT with a drain/collector electrode on one surface and gate and source/emitter electrodes on its opposite surface. The die is mounted on a conductive pad for electrical contact with the drain/collector electrode, with connections to the remaining electrodes on the opposite surface often being made by wire bonding. The pad and wires are electrically connected to a leadframe whose leads project outside a protective housing that is often formed by overmolding the leadframe and die.
Components of the type described above include well-known industry standard package outlines, such as the T0220 and T0247 cases, which are prepackaged integrated circuit (IC) components whose leads are adapted for attachment (e.g., by soldering) to a printed circuit board (PCB). The overmolded housings of these packages protect the die, wire bonds, etc., while typically leaving the lower surface of the conductive pad exposed to provide a thermal and/or electrical path out of the package. Such a path allows the package to be connected to an electrical bus for electrical connection to the PCB, or a heat-sinking mass for dissipating heat from the package. If electrical isolation of the path is necessary, a non-electrically conductive heat-sinking pad is provided between the package and heat-sinking mass. In doing so, the heat-sinking pad increases the thermal resistance of the path, typically on the order of 0.1 to 0.5° C./watt.
A further drawback of packages of the type described above is their size. As an example, in certain high current hybrid vehicle applications, arrays of packages containing MOSFET's in a three-phase configuration are utilized, with two or three devices in parallel per switch. The resulting assembled array may contain, for example, sixteen to twenty-four packages, requiring a relatively large area on the PCB. In high current, high voltage (e.g., 150 to 400 V) hybrid vehicle applications, this situation is exacerbated by the need for paired sets of IGBT's and diodes, with the resulting assembled array twice as many individual packages.
As a solution to the above, commonly-assigned U.S. Pat. No. 6,812,553 to Gerbsch et al. and U.S. patent application Ser. No. 10/707,005 (U.S. Patent Publication 2004/0094828) to Campbell et al. disclose double-sided circuit devices that are packaged between a pair of substrates in such a way as to reduce the overall size of the resulting component while also meeting both current and thermal management requirements. There is a need for assembly processes suitable for mass-producing these and other double-sided circuit components.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a process suitable for mass-producing a double-sided circuit component. The process entails assembling and reflow soldering a double-sided circuit device between a pair of substrate members without the use of separate packaging, wire bonds, etc., that would increase the complexity and size of the component and hinder thermal management of the device.
The process entails depositing a solder material on first surfaces of first and second substrate members, each of which is formed of an electrically-nonconductive material and comprises at least one electrically-conductive area on the first surface on which the solder material is deposited and a second surface oppositely disposed from the first surface thereof. The first substrate member is then placed within a cavity in a receptacle, and a lead member is placed on the first substrate member so that the lead member is supported by the receptacle and a portion of the lead member is aligned with a portion of the electrically-conductive area of the first substrate member. A fixture is then placed on the lead member and over the first substrate member so that the fixture is supported by the receptacle. After aligning a circuit device with the electrically-conductive area of the second substrate member to yield a preliminary assembly, the preliminary assembly is placed in an aperture in the fixture so that a first surface of the circuit device electrically contacts the electrically-conductive area of the first substrate member and a second surface of the circuit device electrically contacts the electrically-conductive area of the second substrate member.
The resulting fixtured assembly, comprising the first and second substrate members, the receptacle, the lead member, the fixture, and the circuit device, is then heated to cause the solder material to melt, flow, and wet the electrically-conductive areas of the first and second substrate members, the portion of the lead member, and the first and second surfaces of the circuit device. Cooling the fixtured assembly yields the double-sided circuit component in which the electrically-conductive area of the first substrate member is solder bonded to the first surface of the circuit device, the electrically-conductive area of the second substrate member is solder bonded to the second surface of the circuit device, and the portion of the lead member is solder bonded to the first and second substrate members so as to be electrically coupled with at least one of the electrically-conductive areas of the first and second substrate members.
In view of the above, the process of this invention is capable of producing the double-sided circuit component in a manner that is suitable for use in high-volume manufacturing with high yields.
Other objects and advantages of this invention will be better appreciated from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are top and side views, respectively, of a double-sided component that can be produced with a process in accordance with the present invention.
FIG. 3 is an exploded view of the component of FIG. 2 .
FIGS. 4 and 5 are plan views of a fixture and boat configured for use in the process of the present invention.
FIG. 6 is an exploded view of the components of FIGS. 3 , 4 and 5 as arranged for undergoing the process of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A double-sided circuit component 10 suitable for use in a process according to the present invention is shown in FIGS. 1 through 3 . The component 10 is shown as comprising a pair of substrates 12 and 14 , a circuit device 18 , and two sets of leads 30 and 32 . From the following it will be appreciated that the component 10 shown in the Figures is intended to be representative of the type of component that can be produced by a process within the scope of the invention, and that the number, configuration, and orientation of the elements of the component 10 can differ from that shown in the Figures, e.g., multiple circuit devices. Examples include the circuit devices disclosed in commonly-assigned U.S. Pat. No. 6,812,553 to Gerbsch et al. and U.S. patent application Ser. No. 10/707,005 (U.S. Patent Publication 2004/0094828) to Campbell et al.
If the component 10 is to be used in a high current and high power application, such as a hybrid or electric vehicle, the substrates 12 and 14 are preferably formed of an electrically-nonconductive material, preferably a ceramic material of the type commonly used in electronic systems such as alumina (Al 2 O 3 ), aluminum nitride (AlN), silicon nitride (SiN), beryllium oxide (BeO), or an insulated metal substrate (IMS) material. Ceramic materials vary in thermal performance, such that the selection of a particular ceramic material for the substrates 12 and 14 will depend at least in part on the thermal requirements of the specific application for the component 10 . Consistent with a high current/power application, each of the outward-facing surfaces 22 and 24 of the substrates 12 and 14 is shown as having an outer layer 26 and 28 , respectively, of thermally-conductive material. The outer layers 26 and 28 may be formed of a solderable material, such as copper, copper alloy, plated (e.g., NiAu) aluminum, etc., to permit soldering of the component 10 to heatsinks (not shown) or other suitable structures. If solder is not required for attachment, such as pressure attachment, other materials can be used for the outer layers 26 and 28 . Furthermore, it is foreseeable that the outer layers 26 and 28 could be eliminated, with the benefit of reducing the thermal resistance of the thermal path through these layers 26 and 28 , and therefore reduced component temperature.
The device 18 may be, for example, a diode, IGBT, MOSFET, or a combination of these devices could be used if more than one device 18 is included in the component. For convenience, the device 18 will be described as a MOSFET, and as such is preferably formed in a semiconductor die, such as silicon. One or more electrodes (not shown) are formed on the upper and lower surfaces of the device. For example, a drain electrode on the lower surface and gate and source electrodes on the upper surface. The device 18 is configured to be mounted between the substrates 12 and 14 so that the drain electrode electrically contacts a conductive pad 40 on the lower substrate 14 and the gate and source electrodes make electrical contact with conductive pads 36 (only one of which is shown) on the upper substrate 14 . To accommodate multiple MOSFET's or other combinations of devices, only minor changes to the substrates 12 and 14 and leads 30 and 32 would be required, as will become evident.
Electrical connections of the leads 30 and 32 to the electrodes of the device 18 are achieved through electrically-conductive contact areas 36 and 40 defined on the inward-facing surfaces 46 and 48 of the substrates 12 and 14 , respectively. On the substrate 12 , an appropriate number of contact areas 36 are defined to individually register with the electrodes on the upper surface of the device 18 , such as the source and gate electrodes of a MOSFET. Similarly, an appropriate number of contact areas 40 are provided on the substrate 14 for registration with the number of electrodes on the lower surface of the device 18 , such as the drain electrode of a MOSFET. Electrically-conductive bonding between the areas 36 and 40 and their respective electrodes is preferably achieved with solder connections. The contact areas 36 and 40 on the substrates 12 and 14 can each be formed by a single conductive layer, e.g., a copper foil, that is patterned or divided by solder stops. The configurations of the areas 36 and 40 can be modified and solder stops used to match the geometry of a variety of integrated circuit devices incorporated into the component 10 .
The leads 30 and 32 are adapted for connecting the component 10 to an electrical bus or other device utilized in the particular application. The leads 30 and 32 can be formed of stamped copper or copper alloy, though other methods of construction are possible. The leads 30 and 32 are depicted as being of a type suitable for use in high current applications (e.g., 200 amperes). For lower current applications, individual lead pins can be used. Each lead 30 and 32 is shown as comprising a plurality of fingers 60 through which physical connection is made to the component 10 and electrical connection is made to the electrodes of the device 18 . In the embodiment shown, the lead 30 is electrically coupled to the electrode(s) on the upper surface of the device 18 through bond pads 56 on the upper substrate 12 and also bonded to the lower substrate 14 through electrically-isolated bond pads 50 on the lower substrate 14 , and the lead 32 is electrically coupled to the electrode(s) on the lower surface of the device 18 through bond pads 52 on the lower substrate 14 and also bonded to the upper substrate 12 through electrically-isolated bond pads 54 on the upper substrate 12 . The pads 50 , 52 , 54 , and 56 can be patterned from the same conductive layers as the areas 36 and 40 on the substrates 12 and 14 . The leads 30 and 32 are preferably soldered to their bond pads 50 , 52 , 54 , and 56 .
In view of the above construction, the component 10 conducts current and uniformly extracts current across its entire face, instead of wire bond connection sites, and therefore has the ability to carry higher currents with less temperature rise than conventional wire bonded and ribbon bonded devices. Also by avoiding wire and ribbon bonding techniques, the component 10 can be readily adapted to enclose various types and configurations of devices. The component 10 also has the advantage of being able to dissipate heat in two directions, namely, up through the upper substrate 12 and/or down through the lower substrate 14 . If both substrates 12 and 14 are used to dissipate heat, the temperature rise of the component 10 can potentially be reduced by about one-half. The solderable outer layers 26 and 28 of the substrates 12 and 14 are isolated from the circuit device 18 by the substrates 12 and 14 . By providing electrically-isolated top and bottom surfaces in this manner, the need for discrete heatsink electrical-isolation pads can be avoided.
It can also be seen from the above that the component 10 does not require a plastic overmold, in that the circuit device 18 is protectively enclosed by the substrate 12 and 14 . Avoiding a plastic overmold reduces internal differences in coefficients of thermal expansion (CTE) within the component 10 , as well as CTE mismatches with components and substrates contacting by the component 10 , thereby improving component life during temperature cycling. If desired, a compliant dielectric encapsulating material can be placed around the perimeter of the component package to seal the edges of the substrates 12 and 14 and the gap therebetween, thereby protecting against contaminant intrusion and improving the electrical isolation properties of the package.
A process for assembling and soldering the parts of the component 10 is represented in FIG. 6 , with two tools 62 and 64 for supporting the components 10 during assembly being represented in FIGS. 4 and 5 . The first tool 62 is a boat specially adapted for the present invention but otherwise generally of the type known for use in reflow processes performed in a belt furnace. For use in the invention, the boat 62 is formed to have any number of sets of three cavities 66 , 68 , and 70 , with the center cavity 68 provided with support pedestals 72 . The boat 62 is also provided with location pins 74 adjacent the cavities 66 and 70 , and an alignment pin 84 by which the second tool, hereinafter a fixture 64 , is aligned with the boat 62 . The fixture 64 is formed to have sets of three aperture 76 , 78 , and 80 corresponding in number to the cavities 66 , 68 , and 70 of the boat 62 , with the center cavity 78 provided with support pedestals 82 . The fixture 64 is also provided with an alignment hole 86 for mating with the alignment pin 84 of the boat 62 .
The process of assembling and soldering the double-sided circuit component 10 of FIGS. 1 through 3 generally entails depositing a solder paste on the contact areas 36 and 40 and bond pads 50 , 52 , 54 , and 56 of the substrates 12 and 14 . The substrate 14 is then placed within one of the center cavities 68 in the boat 62 so as to be supported within the cavity 68 by the recessed pedestals 72 . The leads 30 and 32 are then placed on the boat 62 to span the cavities 66 and 70 thereof and so that their fingers 60 are individually aligned with the bond pads 50 and 52 of the substrate 14 , the alignment of which is assured by mating location holes 34 of the leads 30 and 32 with the location pins 74 of the boat 62 . The fixture 64 is then placed on the leads 30 and 32 and over the substrate 14 so that the fixture 64 is supported by the boat 62 and its alignment hole is mated with the alignment pin 84 on the boat 62 . The portions of the fixture 64 separating the center aperture 78 from the other apertures 76 and 80 preferably contact and immobilize the leads 30 and 32 adjacent their fingers 60 , and the rim of the fixture 64 preferably contacts and immobilizes the portions of the leads 30 and 32 in which the location holes 34 are formed.
The next step is to position the substrate 12 with its surface 46 facing up, orient the device 18 so that its upper surface (as viewed in FIGS. 2 , 3 , and 6 ) is facing down, align the electrode(s) on the upper surface of the device 18 with the contact area 36 of the substrate 12 , and then physically place the device 18 on the substrate 12 to yield what may be termed a preliminary assembly. The preliminary assembly is then inverted to be device-down (as seen in FIGS. 2 , 3 , and 6 ) and placed in the center aperture 78 of the fixture 64 so that the substrate 12 is supported within the aperture 78 by the pedestals 82 , the electrode(s) on the lower surface of the device 18 electrically contact the contact area 40 of the substrate 14 , and the bond pads 54 and 56 on the substrate 12 contact the fingers 60 of the leads 30 and 32 so that the fingers 60 of the leads 30 and 32 are between aligned pairs of the bond pads 50 , 52 , 54 and 56 .
It can be appreciated that the process described above can be performed to simultaneously place parts in the boat 62 and fixture 64 to produce four additional components 10 , and that any number of components 10 could be processed by fabricating the boat 62 and fixture 64 to have the desired number of cavities 66 , 68 , and 70 and apertures 76 , 78 , and 80 . The fixtured assembly is then ready for a solder reflow operation, such as by transporting the boat 62 and the parts supported thereby through a belt oven. Notably, the individual parts of the component 10 are supported and held together with the boat 62 and 64 solely under the force of gravity. During reflow, the solder paste that was deposited on the contact areas 36 and 40 and bond pads 50 , 52 , 54 , and 56 of the substrates 12 and 14 melts, flows, and wets the contact areas 36 and 40 and the bond pads 50 , 52 , 54 , and 56 , the electrodes of the device 18 aligned with the contact areas 36 and 40 , and the fingers 60 of the leads 30 and 32 aligned with the bond pads 50 , 52 , 54 , and 56 . Upon cooling the fixtured assembly, the molten solder forms solder connections that solder bond the contact area 36 and 40 of the substrates 12 and 14 to the electrodes of the device 18 and the fingers 60 of the leads 30 and 32 to their respective pairs of bond pads 50 , 52 , 54 , and 56 .
While the invention has been described in terms of a preferred embodiment, it is apparent that other forms could be adopted by one skilled in the art. Accordingly, the scope of the invention is to be limited only by the following claims. | A process for producing a circuit component having a double-sided circuit device between a pair of substrates. The process entails depositing a solder material on contact areas on surfaces of the substrates, placing a first of the substrates within a cavity in a receptacle, and then placing a lead member on the substrate so that the lead member is supported by the receptacle and a portion of the lead member is aligned with a portion of the contact area of the substrate. A fixture is then placed on the lead member and over the substrate so that the fixture is supported by the receptacle. After aligning the circuit device with the contact area of the remaining substrate, the substrate-device assembly is placed in an aperture in the fixture so that a surface of the device electrically contacts the contact area of the first substrate and the opposite surface of the device electrically contacts the contact area of the second substrate. The resulting fixtured assembly then undergoes reflow. | 7 |
BACKGROUND OF THE INVENTION
1. Field of Use
The present invention relates generally to medical imaging equipment. More specifically, it is directed to a film cassette holder for radiological imaging, which facilitates adjustably positioning imaging film adjacent, and separately configurable from, x-ray imaging equipment, and is used in conjunction therewith to produce a radiograph image on said film.
2. Description of the Related Art
Medical imaging, and particularly the use of roentgen rays, and films developed by exposure thereto, have been known for decades. It is well known that such equipment is generally cumbersome due to size constraints inherent in the equipment itself, and particularly the shielding required. Consequently, elaborate provisions have conventionally been provided for adjustability and directability of the imaging equipment to capture the various particular views of a patient's anatomy that may be desired by an attending physician.
Furthermore, because of the difficulty of adjusting the orientation of such equipment as a result of its bulk and weight, it has often been the practice of radiologists to adjust the relative positions of the patient, imaging film (enclosed in a film cassette or otherwise protected from ambient radiation), and the equipment's radiation source so as to obtain the desired medical imaging result. This, too, however, is difficult in many cases, and further can be uncomfortable (if not painful) for the patient depending upon the particular affliction involved and area of the anatomy being imaged in a particular instance.
Those concerned with the art have recognized the desirability of providing greater adjustability in the relative orientations and positional relationships of the source of roentgen rays or other radiation to the patient and the film to be exposed in order to facilitate more convenient imaging of the portion of anatomy of the patient of interest. For example, these provisions include being able to position and orient the patient in a number of possible positions by changing the orientation and/or the position of the table of the imaging equipment whereon the patient, or the desired portion of the patent's anatomy, is placed, said table containing or supporting the film cassette containing film to be exposed, and correspondingly changing the position and/or orientation of the radiation source. However, provisions for moving the imaging equipment have not provided medical imaging of this type which is, in all cases, convenient or free of discomfort for the patient. Because of its bulk and weight, changes in position and orientation of the equipment occur relatively slowly in conventional equipment. Valuable time is lost changing configurations, or rather, the patient is required assume uncomfortable or inconvenient positions during imaging processes.
In response to these and other concerns, cassette holders have been devised to position the film cassette in relation to the patient and the source of radiation, such cassette holders being independent devices. For example, certain conventional cassette holders comprise a wheeled, vertically adjustable stand, having a transverse swinging boom incorporating a cassette tray at one end. Said cassette tray is usually pivotable with respect to said boom. To counter the weight of the boom and cassette tray and an inserted cassette, ballast may be provided at the opposite end of such a conventional boom.
Such conventional cassette holders provide increased flexibility and convenience in medical imaging, but such cassette holders may inherently be somewhat unstable, requiring the patient to manually steady the cassette during imaging. For example, such steadying is conventionally required in a tangential (axial) projection of the patella, for example. Alternately, the operator of the imaging equipment may use towels or other materials to position and steady the film cassette, or simply have the patient hold the film cassette without using a cassette holder. This use of towels and the like is common, for example, in the axial projection of the intercondyloid fossa.
Moreover, due to the above-mentioned ballasting, and/or rigidity desirable in conventional cassette holders, such conventional cassette holders can be themselves quite heavy and cumbersome. These considerations make these conventional cassette holders inconvenient to use in certain applications.
What is recognized as desirable, and is provided by the present invention, is a way to more conveniently position and orient an X-ray or other radiation responsive film cassette in relation to a radiation source and a portion of the patient's anatomy to be imaged for convenient, and more comfortable for the patient relative orientation and positioning of the film, patient, and radiation source.
SUMMARY OF THE INVENTION
The X-ray film cassette holder of the present invention comprises a base, as well as an adjustably expandable mounting frame incorporating two upwardly expandable risers releasably lockable in a plurality of expanded positions, said risers separated by a releasably lockable variable distance, and two film cassette clamps, each of which is pivotably carried by one of said upwardly expandable risers, and releasably lockable in fixed relation thereto.
The cassette holder, in a more detailed aspect, also incorporates a cassette tray pivotably and releasably mounted between said risers, adapted to receive and carry a film cassette; and locking screws pivotably carrying said cassette tray, said locking screws releasably engaging said risers and said cassette tray and releasingly holding them together in a releasable fixed positional and rotational relationship, to provide an adjustable fixed mounting of said film cassette in said cassette tray. The cassette holder of the invention thereby provides rotational positioning in two orthogonal axes, as well as translational positioning in 3-space, and can be placed on the table of existing X-ray or other radiation imaging equipment, or otherwise adjacent such equipment, and can be conveniently positioned with respect to the patient and the radiation source so as to provide a convenient orientation of the film for imaging the desired portion of the patient's anatomy.
In a further, more detailed, aspect, the frame is adjustable to accommodate different sizes of radiation responsive imaging film cassettes. In particular, different film sizes are accommodated by the film cassette holder frame telescoping to the desired distance between attachment points comprising the cassette clamps or points of attachment of a cassette tray of appropriate size. Subsequently, the film cassette is inserted in the tray, or the film cassette clamps and the cassette releasably fixed in position and angulation by tightening locking screws.
Again in a further more detailed aspect, the cassette holder of the invention allows the film cassette to lockably rotate about an axis generally parallel to a plane defined by the table of the x-ray equipment or other surface upon which the base of the cassette holder is placed. The mounting bracket is adjustable in a direction perpendicular to the plane defining the base to allow the film to be raised or lowered with respect to the table of the equipment or other surface irrespective of its rotational relationship to the table of the x-ray imaging equipment or other surface. Translational and rotational adjustment of the cassette holder on the table or other surface provides the further degrees of freedom of movement for complete adjustability of position and orientation within reasonable and usable space in proximity to the source of radiation. This combined with its relatively small size allows for convenient placement of the patient and the film cassette for more convenient imaging of the desired portion of the patient's anatomy.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a film cassette
FIG. 2 is an exploded isometric view of the cassette. holder of FIG. 1 showing further details of construction;
FIG. 3 is an isometric view of the film cassette holder of FIG. 1 of the invention illustrating loading of a film cassette tray disposed in an inclined orientation with respect to the rest of the film cassette holder;
FIG. 4 is an isometric view of the cassette holder of FIG. 1 showing vertical loading of a film cassette;
FIG. 5 is an isometric view of the cassette holder of FIG. 1 showing loading of a film cassette in film cassette clamps of the cassette holder;
FIG. 6 is an enlarged perspective fragmentary view of a alternate embodiment of cassette holder of the invention showing a circular scale associated with a film cassette clamp;
FIG. 7 is an enlarged perspective view of a portion of the cassette holder of the invention of an alternate embodiment of cassette holder of the invention showing a circular angulation scale associated with a film cassette tray;
FIG. 8 is an enlarged perspective exploded fragmentary view of a portion of the film cassette holder of FIG. 7 showing details of construction; and
FIG. 9 is an enlarged perspective view, shown partially in cutaway, of the film cassette holder of the alternate embodiment of the film cassette holder of FIGS. 7 and 8 showing further details of construction.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2 of the accompanying drawings, which are provided by way of example and not by way of limitation, the invention is embodied in an x-ray film cassette holder 10 having a base 12, a frame 14 having two risers comprising upright sleeves 16, 18 and an expandable transverse portion 20 connecting the two upright sleeves 16, 18 at the base 12. The expandable transverse portion comprises a level sleeve 22 and a level telescoping element 24. The base 12 is split in two pieces, a first base portion 26, to which is attached the level sleeve 22 and one of the upright sleeves 16. A second base portion 28 is attached to the level telescoping frame element 24 and upright sleeve 18. Thus the cassette holder is expandable, and the configuration provides for mounting of various sizes of film cassettes (not shown).
The level telescoping element 24 is slidably engaged within level sleeve 22, and is lockable with respect thereto by means of a frictional locking screw 30. This arrangement allows the second base portion 28, the level telescoping element 24 and upright sleeve 18 to move laterally with respect to the rest of the frame comprising the first base portion 26 level sleeve 22 and upright sleeve 16. The frictional locking screw, which allows the level telescoping element's position with respect to the level sleeve to be releasably fixed, is conventional in the illustrated embodiment, comprising a threaded screw element which engages a threaded hole (not shown) in level sleeve 22 to fictionally engage the level telescoping element by applying a lateral force thereto in a conventional manner. It will be apparent to one skilled in the art that the illustrated frictional locking screw 30 could be replaced by other locking devices, for example, by a conventional "quick release" lever engagement employing a force applying element (not shown) which is moved in and out of frictional engagement with the level telescoping element 24 by actuating a hinged locking lever (not shown).
Upright sleeves 16 and 18 likewise slidably receive upright riser telescoping elements 32 and 34. The position of each upright riser telescoping element can be fixed by tightening frictional locking screws 36 and 38. As with the frictional locking screw 30 associated with the level sleeve 22, frictional locking screws on the upright sleeves 16, 18 could be replaced by other means of fixing the relative positions of the upright telescoping elements and the upright sleeves; for example, by using "quick release" locking levers as mentioned in connection with level sleeve 22 and level telescoping element 24 above.
Upright telescoping elements 32 and 34, as well as level telescoping element 24, each embody a channel, 40, 42 and 44 respectively for receiving the frictional locking screws 36, 38, and 24 respectively. These channels serve to further stabilize the respective telescoping elements, particularly in preventing relative rotational movement between the upright telescoping elements 32 and 34 and upright sleeves 16 and 18, due to deformation of the upright sleeves, which are slotted along one side as will be discussed below, and, therefore, relatively more susceptible to deformation. Also, the channels 40, 42 and 44 somewhat mask surface denting and scarring of the respective telescoping elements due to engagement by the frictional locking screws 30, 36 and 38 respectively.
Each of two film cassette retaining clamps 46, 48 are pivotably attached adjacent the upper end of upright riser telescoping elements 32 and 34 respectively. These film cassette retaining clamps are, in the illustrated embodiment, a C-shaped bracket 50, 52 attached to upright riser telescoping elements 32 and 34 by frictional locking screws 54 and 56. When said frictional locking screws are loosened, the film cassette retaining clamps 46 and 48 are rotatable about the axes of the frictional locking screws. When the frictional locking screws are tightened, the C-shaped bracket 50, 52 is held tightly against the upright telescoping elements 32, 34 and are held in a specific angular relationship thereto by friction.
Film cassette retaining clamps 46 and 48 further comprise film cassette bearing plates 58 and 60, incorporated in clamps 46 and 48 respectively. Said bearing plates interact with the C-shaped brackets 50 and 52 to form a clamp 46, 48 to engage the film cassette. The bearing plates are pivotably attached to frictional locking screws 62, 64 in a conventional manner to allow the locking screws to rotate with relation to the bearing plates, yet retain the bearing plates at the end of said locking screws 62 and 64. This may be done, for example, in the illustrated embodiment, by providing an annular groove (not shown) near the end of the frictional locking screws 62 and 64 which is engaged by slotted locking plates 66 and 68 associated with each bearing plate 58 and 60 respectively. The end of the frictional locking screws 62 and 64 interfit with depressions, such as a shallow hole 70, in the back of bearing plate 58, and the inner surfaces of the depression 70 receive applied forces from the frictional locking screw 62 which are distributed by the bearing plate 58 to the cassette holder (not shown) and prevent the locking screws from slipping sideways with respect to the bearing plates. The locking plates 66, 68 are fixedly attached to the bearing plates 58, 60, for example by fasteners (not shown) or adhesives, with the locking screws retained in the slot and depression of the locking plates and bearing plates, respectively, thereby rotatably attaching the bearing plates to the locking screws.
Furthermore, both bearing plates 58 and 60 and C-shaped brackets 50 and 52, at the surfaces where they contact the film cassette holder 50, incorporate a laminated layer of polymeric resin 71, thereon. Said polymeric resin layer comprises the portions of the film cassette retaining clamps 46, 48 actually in contact with the film cassette holder during use. The polymeric resin laminate layer is incorporated for the purpose of reducing scratching and scarring of the film cassette (not shown) during use. Said laminate layers 71 may also be formed of materials adapted to provide improved frictional engagement of the film cassette holder when it is clamped in the film cassette retaining clamps 46 and 48, respectively. Such materials could include, for example, relatively hard material or synthetic rubbers.
As can be appreciated, the distance between upright riser telescoping elements of the frame 32 and 34 can be adjusted. This adjustability allows the cassette holder 10 to accommodate film cassette holders of various sizes.
With the frame of the cassette holder 10 configured so that the upright riser sleeves (16 and 18) and telescoping elements 32 and 34 are in the closest proximity one to another, a standard 14"×17" x-ray film cassette can be accommodated between the film cassette retaining clamps 46 and 48. Moreover, a separate film cassette tray 72 can be positioned between the upright sleeves 16 and 18 by means of frictional locking screws 74 and 76 which are received in, and threadably engage, cylindrical sliders 78 and 80 which are slidably received in upright sleeves 16 and 18 respectively. This film cassette tray is sized to accommodate a standard film cassette in the illustrated embodiment.
A slotted portion 82, 84 of upright sleeves 16 and 18, respectively, allow the film cassette tray with its associated frictional retaining screws 74 and 76 and cylindrical sliders 78 and 80 to be vertically adjustable with respect to the frame of the cassette holder 10. This configuration provides both translational and rotational adjustability of the film cassette tray within the slotted portions of the upright sleeves 16 and 18. As will be apparent, the cassette holder of this invention can accommodate film cassette trays 72 of various sizes due to the adjustability of the distance between upright sleeves 16 and 18.
Referring to FIG. 3, it can be seen that the rotational and translational adjustability of the film cassette tray 72 allows a film cassette 86 to be adjustably positioned within the cassette holder 10. Referring again to FIG. 2 of the drawing figures, further details of the construction of the cassette holder can be seen. A spacing plate 88 is positioned between the level telescoping element 24 and the second base portion 28 to compensate for the wall thickness of level sleeve 22 of the frame of the cassette holder 10.
In further detail, cylindrical sliders 78 and 80 slidably retained in the upright sleeves 16 and 18 respectively, have an annular channel 90 roughly corresponding to the channel 40, 42 provided in the upright telescoping elements 32 and 34 respectively. This annular channel provides clearance for inserting the cylindrical elements in the upright sleeve portions past the frictional locking screws 36 and 38 in upright sleeves 16 and 18 respectively.
Referring now to FIGS. 4 and 5, it will be apparent to one skilled in the art that the cassette holder 10 of the invention will accommodate a film cassette 92 in various orientations so as to conveniently allow imaging of the particular portion of the patient's anatomy (not shown) desired. In FIG. 4, it can be appreciated that a film cassette can be inserted vertically into the cassette holder 10, or as shown in FIG. 5, horizontally, and it will be appreciated that the inclination of the film cassette can be infinitely adjusted to any inclination there-between. Elevation of the film cassette above the base 12 of the frame of the cassette holder is adjustable by adjustable positioning of the upright riser telescoping elements 32 and 34 within upright sleeves 16 and 18 or by positioning the film cassette tray 72 within the extent of slotted portion 82 and 84 of the upright riser sleeves.
As will be apparent to one skilled in the art the cassette holder 10 of the invention could be fabricated from a number of different materials. In a preferred embodiment T-6 aluminum is used. As will also be apparent, various surface treatments may be employed, such as grey hard anodized, black anodized, powder coat, or clear coat finishes.
Alternatively, other materials, such as steel and other metals and metal alloys, resins, fiber-reinforced resins, and/or other composites, may be employed, which materials may have weight and/or strength advantages. However, as will be apparent to one skilled in the art, in the illustrated embodiment the cassette holder may be manufactured economically from pre-formed extrusions, sheet, and other stock aluminum parts readily available in the United States and throughout the world. The relatively light weight, and ease of machining or otherwise working aluminum, combined with its resistance to corrosion, are other factors making the material desirable for this application.
Referring to FIGS. 6, 7, 8 and 9, it can be appreciated by one skilled in the art that the particular inclination of the film cassette with respect to the base could be indicated by means of the addition of inclination indicative scales embodied in the cassette holder 10. Referring specifically to FIG. 6, with respect to film cassette retaining clamps 46 and 48, conventional circular scale could be employed in conjunction with a circular scale 98 could be employed in conjunction with an indicator 100 positioned on each of the upright telescoping elements 32 and 34 respectively, to provide a readout of the angulation of the film cassette 92 with respect to the base 12. Such a scale and indicator could be, for example, painted, stamped or etched, or defined by other variations of the surface 5 treatment of the material from which the cassette holder is formed.
Furthermore, referring specifically to FIGS. 7, 8, and 9, such angulation indication could be provided for the film cassette tray 72, in the illustrated embodiment of the accompanying drawings. With reference to these figures, a circular scale ring 102 is positioned between the film cassette tray 72 and an upright telescoping element 32 or 34. The circular scale ring 102 embodies one or more positioning pins 104 which interfit with the slotted portion 82, 84 of the upright sleeves 16 or 18 respectively, to hold the circular scale ring 102 in fixed angular relation to the base 12 of the cassette holder 10. An indicator 106 is provided on the film cassette tray 72 to indicate angulation of the film cassette tray with respect to the base of the cassette holder 10. The scale and indicator markings are formed as described above by treating the surface of the materials from which they are formed in a conventional manner. A washer 107 may be employed to space the cassette tray 72 away from the scale ring 102, reducing scarring of the scale by abrasion occasioned by the rotation of the tray. As will be appreciated by those skilled in the art, other methods of providing an indication of relative angulation could be provided, including, for example providing markings directly on the cassette clamps 46, 48 and upright telescoping elements 32, 34, and likewise directly on the cassette tray 72.
Thus, it can be seen that the film cassette holder 10 of the present invention provides for convenient placement of a film cassette adjacent a patient for imaging of a desired portion of the patient's anatomy, and provides convenient adjustable fixed support for a film cassette.
While the invention has been shown and described with respect to a specific embodiment thereof, it will be apparent that other variations and modifications of the embodiment shown and described herein could be employed within the intended spirit and scope of the invention. Accordingly, the invention is not to be limited in scope and effect except by the appended claims. | An X-ray film cassette holder which is small, lightweight, simple and economical to construct and use, having a base carrying an expandable frame incorporating two upwardly expandable risers releasably lockable in a plurality of expanded positions, said risers separated by a releasably lockable variable distance; and two film cassette clamps, each of which is pivotably carried by one of said upwardly expandable risers, and releasably lockable in fixed relation thereto, as well as provision for releasably lockable rotatable mounting of a cassette tray sized within a range determined by the variable distance between said risers on said frame, collectively adapted to hold cassettes steadily in a range of vertical positions above a surface whereon it is placed, at any inclination, and being rotatable on said surface, providing desirable adjustability for positioning an X-ray film cassette adjacent a portion of a patient's anatomy for convenient imaging thereof. | 6 |
TECHNICAL FIELD
[0001] The present invention relates to a novel antimicrobial composition, a disinfectant, and method of preparing same comprising use of any of the C1-C4 monohydric alcohol esters of C8 to C22 fatty acids, and most preferably the C1-C4 monohydric alcohol esters of C8 to C12 fatty acids, namely, caprylic, capric and lauric fatty acids or their combinations as the main active ingredients, with or without one or more additional ingredients. The invention also includes methods of disinfection using the said disinfectant.
BACKGROUND OF THE INVENTION
[0002] There is a heightened awareness of the dangers posed by various infectious diseases today. The cross-border spread of various diseases like bird flu, human influenza, and antibiotic resistant tuberculosis to name just a few has increased the need for effective countermeasures that are both safe and effective.
[0003] Globalization has resulted in unprecedented movement of people across long distances creating the possibility of extensive spread of pathogens. Also the widespread commercialization of animal husbandry has lead to huge losses in terms of flocks being culled to protect against bird flu which has spread globally.
[0004] Additionally, hospitals worldwide are having to deal with in-house or “nosocomial” infections. These infections, which are acquired by patients during hospital stays, are caused largely by microbial contamination of surfaces, and are characterized by being typically antibiotic resistant, and hence potentially deadly.
[0005] Thus, the importance of safe, yet highly effective antimicrobial compositions can be easily appreciated by those who are expert in the field as well as by laypersons. The application of an effective and safe to use antimicrobial on various surfaces through which the spread of potentially deadly microbes can be halted is increasing in importance.
[0006] Antimicrobials using fatty acid monoesters of glycerol and propylene glycol have been disclosed in U.S. Pat. Nos. 5,460,833 and 5,490,992. These monoesters show effectiveness against a broad range of microorganisms but are expensive to manufacture. U.S. Pat. No. 6,699,907 also teaches the use of propylene glycol in combination with medium chain fatty acids as antimicrobials.
[0007] The present invention is a novel composition that is economic and meets the safety, as well as effectiveness criteria for modern antimicrobials especially for use in agricultural, food processing, healthcare, security, manufacturing, cosmetic, and domestic applications.
[0008] Throughout this specification, unless the context does not permit that meaning, mention of a singular, with or without the phrase “one or more of” shall include pleural also of the same or any of functional equivalent of the same, any homologue or analogue of the same and also includes mention of any one of a homologue or an analogue them or more of them separately or in a combination. Thus, mention of “a C1-C4 monohydric alcohol” includes mention of any one or more than one C1-C4 monohydric alcohols, including Methanol, Ethanol, Propanol and Butanol either separately or in combination. Conversely, unless context does not permit, use of a plural also includes mention of a singular or any one of a homologue or analogue or equivalent of the same. Thus mention of “C1-C4 monohydric alcohols” includes use of any one of C1-C4 monohydric alcohol also; or a mention of “emulsifiers and surfactants” includes use of only one of any of an emulsifier and/or a surfactant or a substance that can discharge the function of an emulsifier or a surfactant, whether specifically mention or not in the specification. Further, description of the embodiments, examples, compositions described in this specification are for the illustrative purpose only and are not to be construed to limit the scope of subject matter that is inherent in the claims and any variations that are obvious to a person skilled in the art and any possible equivalent and not expressly mentioned in this specification are construed to be included within the scope of claims.
SUMMARY OF THE INVENTION
[0009] In the following are described embodiments of this invention in brief.
[0010] In broadest aspect, this invention embodies one or more of an antimicrobial composition comprising a monohydric alcohol ester of a fatty acid, further comprising one or more of a C1-C4 monohydric alcohol ester of one or more of a fatty acid including a C8 to C22 fatty acid; most preferably the C1-C4 monohydric alcohol ester of one or more of a C8 to C12 fatty acid including a caprylic, capric, lauric fatty acid and their mixture; the said fatty acid being sourced from chemical synthesis or from a natural source including coconut oil.
[0011] This invention also embodies one or more of a method of using a composition of this invention for disinfection of a surface of an article or an article itself against a broad spectrum of microorganisms.
[0012] This invention also embodies a method of using a composition of this invention for facilitating the reduction, control or elimination of a threat posed by one or more of a microorganism by reducing their level in various situations and an application including agricultural processing, food processing, a healthcare application and the like, manufacturing, and domestic situations and applications. Certain embodiments of the present invention are also safe for human and animal consumption thereby widening the areas of application of the composition and method.
[0013] A composition of the present invention contains one or more of a C1-C4 monohydric alcohol ester of caprylic, capric or lauric fatty acid and their mixture including those found in C1-C4 monohydric alcohol esters of coconut oil.
[0014] In a further embodiment of this invention, a composition of this invention includes its use in a concentrated form; more preferably, mixed in an aqueous or non-aqueous vehicle before use.
[0015] In yet further embodiment of this invention, a composition may contain one or more of a food-grade ingredient that is Generally Regarded as Safe (GRAS).
[0016] Additionally, this invention also includes a composition that may contain one or more of an essential oil extracted from a plant including but not limited to clove ( Syzygium aromaticum L.), cinnamon ( Cinnamomum zeylanicum Blume.), basil ( Ocimum sanctum L.), lemon grass ( Cymbopogon citrates DC.), pepper ( Piper nigrum L.), cardamom ( Cardamomum officinale Salis.), ginger (Zingiber officinale Rose.), coriander seed ( Coriandrum sativum L), orange peel—including D-Limonene—( Citrus species), sage ( Salvia officinalis L.), pomegranate ( Punica granatum L.), etc.
[0017] Additionally the composition of this invention may also contain a phenolic compound including but not limited to Butylated Hydroxtoluene (BHT), Butylated Hydroxanisole (BHA), and Tertiary Butyl Hydroquinone (TBHQ).
[0018] Additionally, the a composition of this invention may also contain an alpha hydroxy acid including but not limited to a lactic acid, malic acid, glycolic acid, citric acid and tartaric acid as well as one or more of a beta hydroxy acid, salicylic acid as a synergist for organisms like E. coli , which may also act as an enhancer against many other microorganisms.
[0019] Additionally, a composition of this invention may contain one or more of a chelator including but not limited to the a sodium, potassium, calcium, or magnesium salt of ethylenediaminetetraacetic acid (EDTA), gluconic acid and its salts, glycolic acid and its salts, citric acid and its salts, and/or another chelator known to the art.
[0020] Additionally, a composition of this invention may contain one or more of an emulsifier, and/or a surfactant including but not limited to a sorbitan ester of a fatty acid, a polyoxyethylene sorbitan ester of a fatty acid, a fatty acid alkanolamide, a nonyl phenol ethoxylate, a sugar ester, an ethoxylated fatty alcohol, an ethoxylated fatty acid, an ethoxylated & propoxylated aliphatic fatty acid, an alkyl glucoside, a polyglucoside, a fatty acid ethoxylate, a salt of an acyl lactylate, a salt of dioctyl sulphosuccinate, and a variety, of other suitable nonionic, cationic, anionic, and zwitterionic surfactant and the like. An emulsifier and/or a surfactant of the invention renders the antimicrobial ingredient miscible in water through emulsification and as such allows for the dilution of a concentrated composition. A surfactant may also, as the need demands, serve as a surface cleaner, and to increase the penetrating power of an antimicrobial composition by reducing the surface tension when used on a substrate with a hard to reach area. An emulsifier and a surfactant is typically amphiphilic, which means that its molecule contains one or more of a distinct hydrophilic and a hydrophobic region.
[0021] Additionally a composition may contain one or more of a C1-C10 monohydric alcohol.
[0022] Additionally a composition of this invention may contain one or more of a gel and a gelling agent, a thickener, and a viscosity improver of various kinds. A thickener, gelling agent, and a viscosity improver includes but is not limited to sodium carboxymethylcellulose, xanthan gum, corn starch, petrolatum, etc.
[0023] Additionally a composition may contain one or more of a rapidly evaporating volatile solvent.
[0024] Additionally a composition may be mixed with a powder including but not limited to calcium carbonate, talc, starch, zinc oxide, titanium dioxide, dolomite, etc. to form powdered compositions capable of being handled and/or being applied the said composition as a dry powder.
[0025] Additionally, a composition may also be in the form of single component, or a two-component system, or even a multi component system that may be made available as a kit.
[0026] Additionally a composition may contain water.
[0027] A composition may be in one or more of a form in which an antimicrobial composition can be prepared and applied to achieve an anti-microbial effect, including but not limited to a form of a liquid—as a liquid concentrate, a water-based emulsion, an alcohol-based liquid, a nano-emulsion—as a thickened gel, as a cream or a lotion, as a powder, incorporated in a wax, and the like.
[0028] A composition may be also in the form of a nano-emulsion.
[0029] A composition may also be incorporated into a cloth, paper, or a porous fabric suitable for use as an antimicrobial wipe, or a bandage, or a dressing for skin or any other substrate.
[0030] Alternatively, the present invention includes a method to disinfect a substrate through contacting the said substrate with a concentrated composition. The said substrate may be a food substrate or a non-food substrate.
[0031] In another aspect, the present invention includes a method wherein a surface is disinfected through contact with a water diluted mixture of the composition. The said substrate may be a food substrate or a non-food substrate.
[0032] In another aspect, the present invention includes a method wherein a substrate is disinfected through contact with a non-water diluted mixture of the composition. The said substrate may be a food substrate or a non-food substrate.
[0033] In another aspect, the present invention includes a method to disinfect a substrate through contacting the said surface with the concentrated composition. The said substrate may be human tissue or animal tissue. The said human tissue or animal tissue may be a live tissue or a dead tissue.
[0034] In another aspect, the present invention includes a method to disinfect a substrate through contacting the substrate with a water-diluted mixture of the composition. The said substrate may be human or animal tissue. The human tissue or animal tissue may be a live tissue or a dead tissue.
[0035] In another aspect, the present invention includes a method to disinfect a substrate through contacting a substrate with a non-water diluted mixture of the composition. The said substrate may be human or animal tissue. The human tissue or animal tissue may be a live tissue or a dead tissue.
[0036] In another aspect, the present invention includes a method wherein an undiluted composition is mixed with food in order to impart antimicrobial protection to the food article, or to provide residual protection to the food article once the composition has been added to the food item.
[0037] In another aspect, the present invention includes a method wherein a water-diluted composition is mixed with food in order to impart antimicrobial protection to the food article, or to provide residual protection to the food article once the composition has been added to the food item.
[0038] In another aspect, the present invention includes a method wherein a non-water diluted composition is mixed with food in order to impart antimicrobial protection to the food article, or to provide residual protection to the food article once the composition has been added to the food item.
[0039] In another aspect, the present invention includes a method wherein a water-diluted composition is used to disinfect the surfaces of an enclosed space, the said enclosed space being a room, a chamber, or any other enclosed space in need of disinfection.
[0040] The invention also includes the ability of the said composition to impart residual antimicrobial effectiveness to a surface to which it has been applied.
DETAILED DESCRIPTION OF THE INVENTION
[0041] The present invention relates to an antimicrobial composition and a method for its use in eliminating or controlling microbial contamination on a wide variety of substrates, encompassing a broad range of one or more applications.
[0042] The said antimicrobial composition may be used to reduce or eliminate microbial contamination on a surface such as a metallic surface including but not limited to steel, copper, aluminium, and one or more of their respective alloys; on a surface made of one or more of a polymeric material including but not limited to a polyethylene, a polypropylene, a nylon, a polylactate, a polyglycolate, and a polyacetate; on a hard surface including but not limited to a medical device and appliance, a countertop, a tabletop, a floor, a ceramic surface including but not limited to a tub, a bath, a sink; and on a woven and non-woven fabric including a synthetic and a non-synthetic.
[0043] The said antimicrobial composition may also be used on a human tissue or other mammalian tissue including but not limited to skin, various types of a wound, and a mucus membrane.
[0044] The large variety of one more of a substrate allows for the application of the said antimicrobial in a broad range of applications including a commercial application in an industry such as agriculture, food processing, healthcare, manufacturing, as well as in domestic situations and applications. Agricultural application includes but is not limited to equipment cleaning and surface treatment of agricultural produce. A food processing application may include without being limited to equipment cleaning, surface treatment of a processed foods or foods under process, and mixing of an antimicrobial composition of this invention into a processed food item. A healthcare application includes, without being limited to, decontamination of one or more of a surface including surface of a medical instrument, a hospital or a clinic, a glove, skin, a clean room, an operating room surface and the like. A manufacturing application includes but, without being limited to, decontamination and maintenance of asepsis in a clean room and a surface in general. A domestic situation may include, without being limited to a kitchen disinfection, bathroom disinfection, hand and body cleaning, food cleaning and decontamination.
[0045] A percentage concentration of one or more of an ingredient or a component of the present invention mentioned below is expressed as total weight-percent of a concentrated formulation, which may or may not be subsequently diluted with water or another solvent prior to end use.
[0046] One or more of a fatty acid ester of the present invention is the principle active ingredient of the present invention. By themselves they exhibit antimicrobial activity against at least one organism. The fatty acid esters of the present invention are comprised of the C1-C4 monohydric alcohol esters of C8 to C22 fatty acids, and most preferably the C1-C4 monohydric alcohol esters of C8 to C12 fatty acids, namely, caprylic, capric, and lauric fatty acids as the active ingredients. Over 60% of the fatty acids in natural coconut oil are C8 to C12 fatty acids. Hence, coconut oil transesterified with any of the C1 to C4 monohydric alcohols is a suitable active ingredient of an antimicrobial formulation of this present invention. Monohydric alcohol esters of C8 to C12 fatty acids and more specifically the methyl and ethyl esters of C8 to C12 fatty acids are approved food flavoring substances under United States CFR Title 21, Part 172, section 172.515.
[0047] A fatty acid ester which forms the principle active ingredient of composition of present invention can be described to have the general formula CH 3 (CH 2 ) m COO(CH 2 ) n CH 3 where m=6, 8, or 10 and n=0, 1, 2, or 3.
[0048] An antimicrobial composition of the present invention may also contain as an optional adjuvant, one or more of an extract of one or more of a plant containing essential oils. An essential oil adjuvant includes, without being limited to, one or more of the following: clove ( Syzygium aromaticum L.), cinnamon ( Cinnamomum zeylanicum Blume.), basil ( Ocimum sanctum L.), lemon grass ( Cymbopogon citrates DC.), pepper ( Piper nigrum L.), cardamom ( Cardamomum officinale Salis.), ginger ( Zingiber officinale Rose.), coriander seed ( Coriandrum sativum L), orange peel ( Citrus species), sage ( Salvia officinalis L.), pomegranate ( Punica granatum L.), etc. Many essential oils have been reported to exhibit antimicrobial activity against specific microorganisms and also work as food preservatives. For example, Nascimento et al, Braz. J. Microbiol. 31:247-256 (2000) report the antibacterial activity of several plant oils against antibiotic resistant strains of bacteria.
[0049] An antimicrobial composition of the present invention may also optionally contain one or more of a phenolic compound including but not limited to Butylated Hydroxytoluene, Butylated Hydroxyanisole, and Tertiary Butylhydroquinone. The quantities or concentrations of these compounds vary depending upon the particular application and may serve as an antioxidant or/and as an additional antimicrobial enhancer, antimicrobial component depending on the concentration used.
[0050] An antimicrobial composition of the present invention may also contain, optionally, as an antimicrobial synergist for E. coli and organisms related to the same in their susceptibility towards a composition of this invention and as an enhancer/augmenter for other unrelated micro-organisms, one or more of an alpha hydroxy acid including, without being limited to, lactic acid, malic acid, glycolic acid, citric acid and tartaric acid as well as one or more of a beta hydroxy acid including without being limited to salicylic acid. Wherever relevant, one or more of an enantiomer of an alpha hydroxy acid may be used effectively as a synergist or as an antimicrobial enhancer. The preferred concentration of the alpha hydroxy acids is between 0.5% and 4% depending on the application. A beta hydroxy acid of this invention includes, without being limited to a salicylic acid. Preferred concentration of the beta hydroxy acid is between 0.5% and 5%.
[0051] Typically a chelator is one or more of an organic compound that binds with a metallic atom or a metallic ion in solution at multiple sites to form a complex usually in the form of a ring. An exemplary chelator useful in a composition of this invention includes, without being limited to, one or more of a sodium, potassium, calcium, and magnesium salt of ethylenediaminetetraacetic acid (EDTA), gluconic acid and its salts, glycolic acid and its salts, citric acid and its salts, and another chelator known to the art. A chelator may be used in preferred concentrations between 0.25% and 5%.
[0052] An emulsifier and/or a surfactant of the invention renders the antimicrobial ingredient miscible in water through emulsification and as such allows for the dilution of a concentrated composition. A surfactant may also, as the need demands, serve as a surface cleaner, and to increase the penetrating power of an antimicrobial composition by reducing the surface tension when used on a substrate with a hard to reach area. An emulsifier and a surfactant is typically amphiphilic, which means that its molecule contains one or more of a distinct hydrophilic and a hydrophobic region.
[0053] Exemplary emulsifiers and surfactants of an antimicrobial composition include, without being limited to, a sorbitan ester of a fatty acid, a polyoxyethylene sorbitan ester of a fatty acid, a fatty acid alkanolamide, a nonyl phenol ethoxylate, a sugar ester, an ethoxylated fatty alcohol, an ethoxylated fatty acid, an ethoxylated & a propoxylated aliphatic fatty acid, an alkyl glucoside and a polyglucoside, a fatty acid ethoxylate, a salt of an acyl lactylate, a salt of dioctyl sulphosuccinate, and a wide variety of one or more of another suitable nonionic, cationic, anionic, and/or zwitterionic surfactant. One or more of a combination of an emulsifier and a surfactant may be used advantageously and in a concentration ranging from 1% to 90%.
[0054] C1 to C10 monohydric alcohols of the invention may be straight chain or branched chain monohydric alcohols of the general formula R—OH where R is a straight chain or branched chain alkyl group containing 1 to 10 carbon atoms. The most preferable monohydric alcohols of the invention are ethanol and isopropyl alcohol given their well-documented safety and efficacy. The alcohols may be used in preferred concentrations ranging from 10% to 80%.
[0055] The physical characteristics of compositions of the invention, depending upon the application, might need to be adjusted. To this end, various thickeners, gelling agents, and viscosity modifiers may be added. The additives mentioned above serve as physical modifiers and have no effect, as such, on the antimicrobial properties of the invention. The thickeners, gelling agents, and viscosity improvers include but are not limited to sodium carboxymethylcellulose, xanthan gum, corn starch, petrolatum, etc.
[0056] Rapidly Evaporating Solvents. Rapidly evaporating solvents are used in many everyday applications like surface coatings, penetrating lubricants, etc. The solvents provide greater penetrability, and, after evaporation, even coatings of the dissolved solutes on surfaces and articles where applied. In the context of the present invention, rapidly evaporating solvents provide a vehicle for the easy application of the compositions of the invention to various substrates and situations. The rapidly evaporating solvents may be various types of aerosols, organic solvents, and refrigerants.
[0057] Powders. In certain applications, the compositions of the present invention may be incorporated into certain commonly used powders. They include but are not limited to calcium carbonate, talc, starch, zinc oxide, titanium dioxide, dolomite, etc.
[0058] In a preferred embodiment, the compositions of the invention may be in liquid form. These liquids may be formulated in the form of concentrates, as water-in-oil emulsions, as pre-diluted emulsions, as ready-to-use alcohol based formulations, as alcohol based concentrates, and as nano-emulsions.
[0059] Given that the concentrated compositions of the invention are made up of a hydrophobic antimicrobial component which constitutes the main ingredient or component, and an enhancer, the two may be packaged separately as two separate components in one single kit. Such a two-component composition constitutes a system that may be mixed in various proportions to arrive at a ready to use composition. Additionally, the concentrated compositions may extend into a three-component system as well. The concentrated compositions made up of two or more components, may be mixed, prior to actual use, with a diluent or combinations of diluents that could be water, an alcohol, a gel, a powder, a solvent, an oil, a polymer, or a thickening agent, or any other substance that is suitable. The diluent or diluents may serve as a vehicle for the concentrated composition.
[0060] The nanoemulsions are characterized by submicron-sized emulsion droplets which render the composition translucent or nearly transparent. Concentrated liquid compositions, either containing alcohol or not containing alcohol, enjoy the advantage of being easily transported, cost-effective, and are easily metered while diluting. Pre-diluted emulsions and alcohol based ready-to-use formulations are preferred embodiments in some applications where a ready-to-use composition is needed, for example, hand disinfection in medical institutions.
[0061] In another preferred embodiment, the compositions of the invention may be in a thickened form. This thickened form may be produced by formulating the composition into a gel. A large number of thickeners or viscosity modifiers are available for this use including the known cellulosic thickeners, various gums, and polymers. Polyethylene glycols of various molecular weights may also be used to provide thickened compositions. Petrochemical-based thickeners such as petrolatum may also be used to produce thickened compositions. The advantage of thickened compositions is apparent in applications where the antimicrobial effect is needed to persist over an extended period of time. Such applications could include the treatment of infections in the nasal cavity, as well as for the control or elimination of microorganisms residing in the vaginal and rectal areas of mammals, and for the treatment of external ear infections.
[0062] In another embodiment, the concentrated compositions may contain a small amount of water. The minor amount of water could be incorporated to form a water-in-oil emulsion within the concentrate. The water could also act as a carrier solvent for any water soluble or hydrophilic enhancers, emulsifiers, surfactants, or other adjuvants and additives. The quantity of water could vary from 0.1 weight-percent to 10 weight percent of the concentrated composition. These concentrated compositions containing small amounts of water may also be in the form of lotions or ointments. The concentrated water-containing compositions may also be diluted by water, alcohol, powders, gels, thickeners, polymers or any other suitable diluents to form ready-to-use formulations.
[0063] In another embodiment, the compositions of the present invention may be in the form of powders. The compositions may be formulated by incorporating the antimicrobial ingredients into commonly used powders such as calcium carbonate, talc, starch, zinc oxide, titanium dioxide, dolomite, etc. to form powdered compositions. The antimicrobial agents may be incorporated into the powders at a minimum concentration of 0.1 weight-percent to 5 weight-percent.
[0064] It will be apparent to those skilled in the art that compositions of the present invention may be combined with antiseptics, antibiotics, antimicrobials, adjuvants, synergists and antimicrobial enhancers existing in the prior art to produce a wide array of compositions with an equally broad range of applications. Indeed, it is conceived that antiseptics, antibiotics, antimicrobials, adjuvants, synergists or antimicrobial enhancers existing in the prior art be combined with compositions of the present invention. It is also contemplated, and obvious to those skilled in the art, that the compositions of the present invention may also contain ingredients that, while not possessing any antimicrobial effect, increase the aesthetic appeal of the compositions, and serve as formulation aids.
[0065] As is evident from the above embodiments, compositions of the present invention may be formulated in an exceedingly large number of ways and methods. Following are non-limiting examples given for the purpose of illustration of compositions of this invention and anti-microbial/disinfection activity of some of them. All proportions and percentages are expressed by weight unless mentioned otherwise. The components and materials used to make the exemplary formulations are commercially available unless otherwise stated. Inventory of materials used is given in Table no. 1 in the following:
[0000]
TABLE 1
Inventory of Materials Used
Desig-
Name of the Ingredient
nation
Source/Supplier
Methyl Laurate
ML12
Subhash Chemicals, Pune, India
Sorbitan Monolaurate
Span 20
Loba Chemie, Mumbai, India
Polyoxyethylene Sorbitan
Tween 20
Loba Chemie, Mumbai, India
Monolaurate
Lactic Acid 88%
LA 88
Qualigens, Mumbai, India
Butylated Hydroxytoluene
BHT
Qualigens, Mumbai, India
Dioctyl Sulphosuccinate
DOSS 50
Badrivishal Chemicals &
50%
Pharmaceuticals, Pune, India
In Polyethylene Glycol 400
Dioctyl Sulphosuccinate
DOSS 70
Rohit Chemicals, Mumbai, India
50%
In Polyethylene Glycol 400
Clove Oil
Clove Oil
Chemical Process Consultants,
Mumbai, India
Orange peel oil
D-
Chemical Process Consultants,
Limonene
Mumbai, India
Polyethylene Glycol 400
PEG 400
Neeta Chemicals, Pune, India
Isopropyl Alcohol
IPA
Neeta Chemicals, Pune, India
Example 1
Preparation of Coconut Oil Methyl Ester
[0066] Coconut Oil Methyl Ester (COME) was prepared in the following manner: 160 grams of methanol was mixed with 3.5 grams of sodium hydroxide (NaOH) and shaken in a closed 250 ml plastic bottle until the NaOH completely dissolved. 910 grams of refined coconut oil in a glass beaker was heated to 50 degrees centigrade over an electric coil heater and the methanol/NaOH mix was added with stirring. The temperature was maintained between 50 and 55 degrees centigrade and the mixture was continuously stirred for 30 minutes. The reaction mixture was then removed from the heat source and allowed to cool for 12 hours. Two distinct layers were observed, an upper layer of coconut oil methyl esters, and a lower glycerin layer. The upper layer of coconut oil methyl esters was then decanted and its pH was measured using commercially available pH paper. Phosphoric acid was added mixed until the pH of the methyl esters was between 7 and 8. The methyl esters were then mixed with 500 grams of water and allowed to settle for 24 hours. The upper layer of methyl esters was then decanted and washed again with 500 grams of water. The upper layer of methyl esters was again decanted and heated to 80 degrees centigrade for 1 hour. The weight of the resultant methyl esters of coconut oil was 804 grams.
Example 2
Concentrated Compositions
[0067] Concentrated formulations were prepared by mixing the ingredients together in a glass beaker while heating on a hot plate. Ingredients were heated to 50 degrees centigrade while manually stirring with a glass rod or stainless until the ingredients formed a clear homogenous mixture.
[0068] Illustrative concentrated compositions are given in Table 2 in the following:
[0000]
TABLE 2
Concentrated Formulations
Composition
Ingredients
1
2
3
4
5
6
ML 12
73.0
45.5
85.0
20.0
70.0
COME
80.0
42.0
Span 20
12.0
9.0
5.0
7.0
3.0
Tween 20
6.8
7.5
5.0
3.0
5.0
DOSS 50
9.0
10.0
18.0
10.0
DOSS 70
13.0
7.5
Clove Oil
22.7
10.0
PEG 400
2.5
2.0
BHT
2.0
1.0
IPA
9.0
Water
4.5
Example 3
Alcohol-Containing Ready-to-Use Compositions
[0069] The ingredients were manually stirred in a glass container until a homogenous, clear mixture was obtained. No external heat was applied. The quantities reported in Table 3 are in weight-percent.
[0000]
TABLE 3
Alcohol-Containing Ready-to-Use Compositions
Ingredients
Composition 7
Composition 8
COME
2.0
2.0
D-Limonene
0.5
0.5
PEG 400
2.0
2.0
LA 88
—
0.5
IPA
95.5
95.0
Example 4
Powder Compositions
[0070] Composition 9: 10 grams of Talcum Powder (Pond's Dreamflower, Hindustan Lever Ltd., Mumbai; Ingredients: Talc, Calcium carbonate, Dipropylene Glycol, Fragrance, Vitamin B3, Vitamin E Acetate, Zinc Oxide) was weighed into a steel bowl. 0.5 grams of Formulation 5 was added to the bowl and mixed into the Talcum Powder until all the clumps disappeared. The resultant powder was free-flowing and without clumps.
[0071] Composition 10: 0.5 grams of Formulation 5, 0.5 grams of PEG 400, 1.2 grams of IPA, and 0.1 gram of LA 88 were shaken in a test tube until a clear homogenous mixture was obtained. The mixture was then added to 10 grams of Pond's Dreamflower Talcum Powder in a microwave safe bowl were mixed together with a glass rod. The mixture was then heated in a microwave oven (LG Grill, India) at 800 watts for 20 seconds. After removal from the oven the formulation was mixed again with a glass rod until the powder was free flowing and clump-free.
Example 5
Ointments
[0072] Composition 11: In a test tube, 1.0 gram of Formulation 5 was combined with 1.0 gram of distilled water and 0.2 grams of LA 88. The mixture was shaken vigorously until a milky white emulsion was formed. 10 grams of commercially available white petrolatum was combined with 0.2 grams BHT and placed in a glass beaker and was heated on a hot plate until melted. The emulsion described above was added and the mixture was stirred vigorously until homogenous. The beaker was then removed from heat and cooled by submerging the bottom third of the beaker in a bowl container water. Stirring was continued until the thickened and cooled mixture reached ambient temperature which was 26 degrees centigrade. The formulation was viscous and did not shed any water upon storage for 3 months.
Example 6
Nanoemulsions
[0073] Composition 12: 100 ml of Composition 4 was processed in a high pressure homogenizer (Niro Soavi, Italy, Model No. NS1001L2K) at between 800 and 1050 bars pressure. An initial dilution ratio of 1 part composition 4 and 3 parts of water was used and passed through the homogenizer 3 times. The resulting emulsion was then further diluted with 4 parts of water and passed through the high pressure homogenizer 5 times. The resulting nanoemulsion was sapphire blue in color, translucent, and contained 6.25% of the antimicrobial composition 5.
Example 7
Microbiological Methods, Tests and Investigations
In Vitro Antimicrobial Efficacy Using Time Kill Procedure
[0074] The following target organisms were included in the tests: E. Coli —ATCC No. 8739; Staphylococcus Aureus —ATCC No. 6538 and Candida Albicans —ATCC No. 10231. The initial inoculum counts for all the organisms were between 10 6 and 10 8 CFUs/ml.
[0075] The testing procedure was according to ASTM E 2315-03 standards and protocols. The exposure times were 2 minutes and 10 minutes. Each test concentration was tested in duplicate and each sample was plated in duplicate.
[0076] The log reduction expresses the efficacy of the antimicrobial formulation against the target organism. The final mean number of Colony Forming Units (CFUs) per ml of test solution at a given exposure time log 10 is calculated as follows:
[0000] Mean No. of CFUs/ml ═ N a =C /( n×D×V )
Where:
[0000]
C=Total number of colonies counted on all plates
V=Sample volume used to prepare the pour plate (1 ml)
D=Dilution factor (0.01)
n=Number of plates taken into account
a=exposure time
[0082] The mean log reduction is calculated using the equation:
[0000] Mean log reduction log 10(N I ×0.01)−log 10 (N a )
[0000] Where N I is the initial organism count
Antimicrobial Efficacy of Methyl Laurate
[0083] Composition 3 was diluted in water at a concentration of 2 weight percent. The formulation was then tested against the target organisms. The results are detailed in Table 4.
[0000]
TABLE 4
In vitro testing log reduction for 2% Composition 3
S. Aureus
E. Coli
Candida Albicans
2 minute log reduction
>6.5
—
2.66
10 minute log reduction
>6.5
2.44
>6.5
Antimicrobial Efficacy of Lactic Acid
[0084] The lactic acid antimicrobial enhancer was tested against the target organisms at 1.0% concentration. The results are given below:
[0000]
TABLE 5
In vitro testing log reduction for 1% LA 88
S. Aureus
E. Coli
Candida Albicans
2 minute log reduction
<2.0
2.36
2.69
10 minute log reduction
<2.0
2.41
2.79
Antimicrobial Efficacy of Composition 3 and Lactic Acid Antimicrobial Enhancer
[0085] Composition 3 and LA 88 were diluted in water at 2% and 1% concentration respectively. The resultant formulation was tested against the target organisms. The results are tabulated below:
[0000]
TABLE 6
In vitro testing log reduction for 2% Composition 3 and 1% LA 88
S. Aureus
E. coli
Candida albicans
2 minute log reduction
>6.5
<2.0
>6.5
10 minute log reduction
>6.5
>6.5
>6.5
[0086] The results of Table 4, 5 and 6 show that the combination of the antimicrobial fatty acid ester and lactic acid possesses greater antimicrobial efficacy than any one of the component alone against all 3 target organisms, that the resulting combined anti-microbial activity against E. coli is significantly more than additive effect of both indicating a synergistic effect of the combination. It is contemplated that this synergistic effect will be apparent against several other organisms as well.
Antimicrobial Efficacy of Composition 2 and Lactic Acid Antimicrobial Enhancer
[0087] Composition 2 and LA 88 were diluted in water at 2% and 1% concentration respectively. The resultant formulation was tested against the target organisms. The results are tabulated below:
[0000]
TABLE 7
In vitro testing log reduction for 2% Composition 2 and 1% LA 88
S. aureus
E. coli
Candida albicans
2 minute log reduction
>6.5
—
>6.5
10 minute log reduction
>6.5
>6.5
>6.5
[0088] The above results show that the combination of the ester antimicrobial composition containing clove oil with lactic acid exhibits antimicrobial efficacy comparable to the synergistic combination of the antimicrobial fatty acid ester and lactic acid. In view of the fact that concentration of Methyl Laurate is about 50% of that used in Composition 3 and is replaced by clove oil, it is clear that the concentration of clove oil used in the composition gives an activity that is comparable to the quantity of Methyl Laurate replaced and Composition 2 has an efficacy that is comparable to Composition 3.
Test for Surface Cleaning Efficacy
[0089] Composition 5 and LA 88 were diluted in water at 2% and 1% concentration respectively. The resultant composition was used to disinfect a variety of surfaces in a room including a granite counter, a stainless steel sink, the top of a refrigerator, and the floor. Sterile swabs were used to recover organisms on the above mentioned surfaces prior to treatment with the antimicrobial composition.
[0090] The surfaces were then contacted with the antimicrobial composition by spraying with a spray bottle and the surfaces wiped clean with a clean cloth. After a half hour, sterile swabs were again used to recover any organisms on the surface. The swabs were transferred to test tubes containing 1% peptone water, vortexed and plated onto blood agar plates and MacConkey agar plates in duplicate and incubated for 48 hours at 35+/−2 degrees centigrade, after which the colonies were counted.
[0091] While the pre-treatment plates showed profuse growth of gram negative bacilli and gram positive cocci, the post-treatment plates no growth at all, except the floor sample which showed 15 colonies of gram positive cocci. The example shows the antimicrobial composition's efficacy as a surface disinfectant with a residual effect.
Disinfection of a Fruit Surface
[0092] Two apples were purchased from the local grocery store. An area of approximately 1 square inch was chosen on each apple. A test suspension containing 100 CFUs/ml of E. Coli ATCC No. 8739 was applied on the chosen area of each apple. The surfaces were allowed to dry. An antimicrobial composition was prepared with 2% Formulation 2 and 1% LA 88. The antimicrobial composition was then applied on the chosen areas of one of the apples and allowed to air dry for 10 minutes. Using sterile swabs, organisms on both the treated areas of the two apples were recovered. The swabs were transferred to test tubes containing 1% peptone water respectively. The test tubes were vortexed to free the cells. Duplicate 1 ml plates were prepared and incubated for 24 hours at 35+/−2 degrees centigrade. The number of colonies on each plate was counted. The plates untreated with the antimicrobial composition had an average of 89 CFUs while the plates treated with the antimicrobial composition had an average plate count of 8 CFUs per plate. | The present invention relates to a novel antimicrobial composition and method comprising any of the C1-C4 monohydric alcohol esters of C8 to C22 fatty acids, and most preferably the C1-C4 monohydric alcohol esters of C8 to C12 fatty acids, namely, caprylic, capric, and lauric fatty acids. Specifically the invention is related to a composition and method to disinfect various surfaces and substrates including the surfaces of food products, animal and human tissue and appendages, inanimate objects of various compositions, and also enclosed spaces. The invention can be incorporated into various media including liquids, gels, powders, paints, sealants, and the like and can be in the form of emulsions including nanoemulsions. | 0 |
TECHNICAL FIELD
[0001] The present invention relates to an in-vehicle fire extinguishing apparatus that performs fire extinguishing by utilizing an air conditioning apparatus that heats or cools the vehicle interior.
BACKGROUND ART
[0002] Conventionally, a fire extinguishing device disclosed in PTL 1 has been known in which, when an abnormality detection sensor detects an abnormality of a storage battery such as an abrupt change in temperature, a flame-retardant refrigerant circulating in a refrigeration circuit in a cooling device is discharged into a battery pack through a discharge pipe. According to PTL 1, by using refrigerant as a fire extinguishing agent, fire extinguishing can be promptly performed even when fire occurs in the storage battery.
CITATION LIST
Patent Literature
PTL 1
Japanese Patent Application Laid-Open No. 2010-110356
SUMMARY OF INVENTION
Technical Problem
[0003] However, in PTL 1, since fire extinguishing is performed when the abnormality detection sensor detects an abnormality, fire extinguishing cannot be performed in the case where the abnormality detection sensor is broken or damaged by impact or the like applied to the vehicle from the outside.
[0004] An object of the present invention is to provide an in-vehicle fire extinguishing apparatus that can surely perform fire extinguishing and the like, by performing the fire extinguishing without using a sensor.
Solution to Problem
[0005] An in-vehicle fire extinguishing apparatus of an embodiment of the present invention is configured to perform fire extinguishing by utilizing an air conditioning apparatus that heats or cools a vehicle interior, the in-vehicle fire extinguishing apparatus including: an incombustible or flame-retardant refrigerant; a compressor that compresses the refrigerant in such a manner as to increase a temperature and a pressure of the refrigerant; a condenser that causes a high-temperature and high-pressure refrigerant compressed by the compressor to release heat; an expansion valve that expands the refrigerant that is caused to release heat by the condenser in such a manner as to reduce the temperature and the pressure of the refrigerant; an evaporator that causes a low-temperature and low-pressure refrigerant expanded by the expansion valve to absorb heat; a circulation path that causes the refrigerant output from the compressor to enter the compressor through the condenser, the expansion valve, and the evaporator; and a fire extinguishing section provided in the circulation path between the expansion valve and the compressor, the fire extinguishing section allowing the refrigerant entered from the circulation path to be output to the circulation path under an environment of a temperature below a predetermined temperature equal to or greater than a guaranteed temperature of a device mounted in a vehicle, and emitting the refrigerant entered from the circulation path to an exterior so as to perform fire extinguishing by being melted under an environment of a temperature equal to or greater than the predetermined temperature.
Advantageous Effects of Invention
[0006] According to the present invention, fire extinguishing and the like can be surely performed, by performing the fire extinguishing without using a sensor.
BRIEF DESCRIPTION OF DRAWINGS
[0007] FIG. 1 is a block diagram illustrating a configuration of an in-vehicle fire extinguishing apparatus according to Embodiment 1 of the present invention;
[0008] FIG. 2 is a perspective view of a fire extinguishing section in Embodiment 1 of the present invention;
[0009] FIG. 3 is a sectional view taken along line A-A of FIG. 2 illustrating a state where a closure section in Embodiment 1 of the present invention is not yet melted;
[0010] FIG. 4 is a sectional view taken along line A-A of FIG. 2 illustrating a state where the closure section in Embodiment 1 of the present invention has been melted;
[0011] FIG. 5 is a perspective view of a charger on which the fire extinguishing section in Embodiment 1 of the present invention is attached;
[0012] FIG. 6 is an enlarged sectional view of a main part of a fire extinguishing section in Embodiment 2 of the present invention;
[0013] FIG. 7 is an enlarged sectional view of a main part of a fire extinguishing section in Embodiment 3 of the present invention;
[0014] FIG. 8 is an enlarged sectional view of a main part of a fire extinguishing section in Embodiment 4 of the present invention; and
[0015] FIG. 9 is an enlarged sectional view of a main part of a fire extinguishing section in Embodiment 5 of the present invention.
DESCRIPTION OF EMBODIMENTS
[0016] In the following, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
Embodiment 1
Configuration of In-Vehicle Fire Extinguishing Apparatus
[0017] A configuration of in-vehicle fire extinguishing apparatus 100 according to Embodiment 1 of the present invention is described with reference to FIG. 1 . FIG. 1 is a block diagram illustrating a configuration of in-vehicle fire extinguishing apparatus 100 according to an embodiment of the present embodiment.
[0018] In-vehicle fire extinguishing apparatus 100 includes compressor 101 , condenser 102 , expansion valve 103 , fire extinguishing section 104 , evaporator 105 , and circulation path 106 .
[0019] Air conditioning section 150 includes compressor 101 , condenser 102 , expansion valve 103 , evaporator 105 , and circulation path 106 . Air conditioning section 150 serves as an air conditioning apparatus, and heats or cools the vehicle interior.
[0020] Compressor 101 compresses refrigerant having entered from evaporator 105 through circulation path 106 so as to increase the temperature and pressure of the refrigerant. Compressor 101 supplies the high-temperature and high-pressure refrigerant to condenser 102 through circulation path 106 . Here, the refrigerant is incombustible or flame-retardant, and, for example, carbon dioxide, HFC-134a or HF0-1234yf is used as the refrigerant. An incombustible refrigerant is difficult to ignite, and does not continuously burn. A flame-retardant refrigerant is difficult to ignite, and even when it is ignited and combustion is continued, the speed is extremely low. In the present invention, an incombustible refrigerant is preferably used.
[0021] Condenser 102 causes the high-temperature and high-pressure refrigerant having entered from compressor 101 through circulation path 106 to release heat so as to liquefy the refrigerant, and supplies the liquefied refrigerant to expansion valve 103 through circulation path 106 . The heat released from the refrigerant in condenser 102 heats up the vehicle interior.
[0022] Expansion valve 103 expands the refrigerant having entered from condenser 102 through circulation path 106 so as to reduce the temperature and pressure of the refrigerant. Expansion valve 103 supplies the low-temperature and low-pressure refrigerant to fire extinguishing section 104 through circulation path 106 .
[0023] Under an environment of a predetermined temperature below a guaranteed temperature of a device mounted on the vehicle (hereinafter referred to as “fire extinguishing start temperature”), fire extinguishing section 104 supplies the low-temperature and low-pressure refrigerant having entered from expansion valve 103 through circulation path 106 to evaporator 105 through circulation path 106 . Under an environment of the fire extinguishing start temperature or above, a part of fire extinguishing section 104 is melted, and the low-temperature and low-pressure refrigerant having entered from expansion valve 103 through circulation path 106 is emitted out of in-vehicle fire extinguishing apparatus 100 , whereby fire extinguishing is performed. Here, the refrigerant having entered fire extinguishing section 104 from expansion valve 103 through circulation path 106 has a pressure higher than that of the outside air. It is to be noted that details of the configuration of fire extinguishing section 104 will be described later.
[0024] Here, examples of the device mounted in the vehicle include a motor, a charger, a battery, and an ECU. A guaranteed temperature of a device includes an operation guarantee temperature and a storage guarantee temperature. The operation guarantee temperature of a device is a temperature at which the device can normally function. When the device is used at a temperature greater than the operation guarantee temperature, the device does not normally operate, or the lifetime of the device is shortened from the guarantee lifetime. The operation guarantee temperature of a device mounted in an electric automobile provided with no engine is, for example, 125° C. In the case where the operation guarantee temperature of a device mounted in an electric automobile provided with no engine is 125° C., the fire extinguishing start temperature is set to, for example, 150° C. In addition, the storage guarantee temperature of a device is a temperature at which the possibility that the device is broken is high. The storage guarantee temperature of a device mounted in an electric automobile provided with no engine is, for example, 150° C. In the case where the storage guarantee temperature of a device mounted in an electric automobile provided with no engine is 150° C., the fire extinguishing start temperature is set to a temperature greater than 150° C. It is to be noted that the fire extinguishing start temperature may be the same as the operation guarantee temperature or the storage guarantee temperature of the device mounted in the vehicle.
[0025] Evaporator 105 evaporates the refrigerant having entered from fire extinguishing section 104 through circulation path 106 such that the refrigerant absorbs heat, and then evaporator 105 supplies the refrigerant having absorbed the heat to compressor 101 through circulation path 106 . When heat is absorbed by the refrigerant in evaporator 105 , the vehicle interior is cooled.
[0026] Circulation path 106 circulates the refrigerant output from compressor 101 through condenser 102 , expansion valve 103 , fire extinguishing section 104 , evaporator 105 and compressor 101 , in the named order.
<Configuration of Fire Extinguishing Section>
[0027] The configuration of fire extinguishing section 104 in Embodiment 1 of the present invention is described with reference to FIG. 2 and FIG. 3 . FIG. 2 is a perspective view of fire extinguishing section 104 in the present embodiment. FIG. 3 is a sectional view taken along line A-A of FIG. 2 illustrating a state where closure section 203 is not yet melted.
[0028] Fire extinguishing section 104 includes fire extinguishing board 201 , void 202 (see FIG. 3 ), and closure section 203 .
[0029] Fire extinguishing board 201 has a plate-shape. Fire extinguishing board 201 is provided with closure section 203 .
[0030] Void 202 is surrounded by wall section 201 a . Refrigerant enters void 202 from circulation path 106 , and the refrigerant having entered void 202 is output to circulation path 106 .
[0031] Closure section 203 is formed of a material different from that of fire extinguishing board 201 . Closure section 203 is formed of a material that is melted by a temperature greater than the fire extinguishing start temperature, and closure section 203 is attached to fire extinguishing board 201 . For example, closure section 203 is formed of a fusible alloy which is used for thermal fuses, and closure section 203 is attached to fire extinguishing board 201 . In addition, closure section 203 may be formed of tin or a solder and attached to fire extinguishing board 201 such that closure section 203 is melted at the fusing point of tin or solder. When closure section 203 is formed of a solder, closure section 203 can be melted at, for example, 183° C.
[0032] Closure section 203 is provided in wall section 201 a that separates void 202 from the exterior in fire extinguishing section 104 . For example, closure section 203 is attached to wall section 201 a by welding. As viewed in the thickness cross-section of wall section 201 a , closure section 203 is formed in a rectangular shape (see FIG. 3 ). When provided in wall section 201 a , closure section 203 seals void 202 from the exterior.
[0033] Under an environment of a temperature below the fire extinguishing start temperature, the state where closure section 203 is provided in fire extinguishing board 201 is maintained. Thus, the refrigerant having entered void 202 from circulation path 106 is output to circulation path 106 without being emitted to the exterior of fire extinguishing section 104 . In addition, under an environment of the fire extinguishing start temperature or above, closure section 203 is melted by heat. Thus, the refrigerant having entered void 202 from circulation path 106 is emitted out of fire extinguishing section 104 . Here, at the time of extinguishing fire, the entirety of closure section 203 is not have to be melted as long as the refrigerant having entered void 202 is emitted out of fire extinguishing section 104 . In view of this, the melting of closure section 203 includes the case where the entirety of closure section 203 is melted and the case where a part of closure section 203 is melted.
[0034] A predetermined pressure is exerted on closure section 203 by the refrigerant having entered void 202 , and therefore, closure section 203 is so provided in fire extinguishing board 201 as not to be dropped off from fire extinguishing board 201 by the pressure of the refrigerant under an environment of a temperature below the fire extinguishing start temperature.
<Fire Extinguishing Method>
[0035] A fire extinguishing method in Embodiment 1 of the present invention is described with reference to FIG. 3 and FIG. 4 . FIG. 4 is a sectional view taken along line A-A of FIG. 2 illustrating a state where closure section 203 has been melted.
[0036] Referring to FIG. 3 , closure section 203 is heated and melted by fire when fire occurs at device 301 , under an environment of the fire extinguishing start temperature or above. When part of closure section 203 is melted, or when closure section 203 is melted and dropped off from fire extinguishing board 201 as illustrated in FIG. 4 , through hole 401 that connects void 202 and the exterior is defined in fire extinguishing board 201 . In this state, the refrigerant having entered void 202 is emitted to device 301 and the area around device 301 from through hole 401 , so as to extinguish the fire.
[0037] At this time, before closure section 203 is melted, wall section 201 a and closure section 203 are under a predetermined pressure exerted by the refrigerant having entered void 202 . Accordingly, the refrigerant which is emitted from through hole 401 when closure section 203 is melted has a certain force caused by the release of the pressure.
<Exemplary Use of Fire Extinguishing Section>
[0038] An exemplary use of fire extinguishing section 104 in Embodiment 1 of the present invention is described with reference to FIG. 5 . FIG. 5 is a perspective view of charger 502 on which fire extinguishing section 104 in the present embodiment is attached.
[0039] As illustrated in FIG. 5 , fire extinguishing section 104 is attached to charger 502 through cover 501 .
[0040] Cover 501 covers the space between fire extinguishing section 104 and charger 502 .
[0041] Between cover 501 and charger 502 , power source circuit section 504 on which device 503 is mounted is housed. On the upper side of cover 501 , fire extinguishing section 104 is attached.
[0042] In FIG. 5 , fire extinguishing board 201 includes pressure-regulating valve 505 . Pressure-regulating valve 505 adjusts the pressure of the refrigerant having entered void 202 exerted on fire extinguishing board 201 .
[0043] In the above-mentioned configuration, when fire is caused by ignited device 503 , closure section 203 is melted. Thus, the refrigerant having entered fire extinguishing board 201 from circulation path 106 is scattered to power source circuit section 504 so as to extinguish fire.
<Effect of the Present Embodiment>
[0044] According to the present embodiment, fire or the like can be surely extinguished by performing fire extinguishing without using a sensor.
[0045] In addition, according to the present embodiment, the closure section has a simple rectangular shape in the thickness cross-section of the wall section forming the fire extinguishing section. Thus, the closure section can be readily formed, and the calculation of the pressure of the refrigerant exerted on the closure section can be easily performed, and in addition, the temperature at which the closure section is melted can be readily set since the calculation of the heat conduction characteristics in the closure section is readily performed.
[0046] In addition, according to the present embodiment, when a pressure-regulating valve is provided in the fire extinguishing section, it is possible to prevent the closure section from being dropped off from the fire extinguishing board by the pressure of the refrigerant exerted on the closure section, under an environment of a temperature below the fire extinguishing start temperature.
<Modification of the Present Embodiment>
[0047] While the closure section has a rectangular shape in the thickness cross-section of the wall section of the fire extinguishing board in the present embodiment, the present invention is not limited to this, and the closure section may have a square shape in the thickness cross-section of the wall section of the fire extinguishing board.
Embodiment 2
Configuration of Fire Extinguishing Section
[0048] The configuration of fire extinguishing section 600 in Embodiment 2 of the present invention is described with reference to FIG. 6 . FIG. 6 is an enlarged sectional view of a main part of fire extinguishing section 600 in the present embodiment.
[0049] As compared with fire extinguishing section 104 according to Embodiment 1 illustrated in FIG. 2 and FIG. 3 , fire extinguishing section 600 illustrated in FIG. 6 includes closure section 601 in place of closure section 203 . It is to be noted that, in FIG. 6 , the same reference numerals are attached to the components same as those in FIG. 2 to FIG. 4 , and the descriptions thereof are omitted. In addition, the in-vehicle fire extinguishing apparatus according to the embodiment of the present embodiment has the same configuration as that illustrated in FIG. 1 , and the description thereof is omitted.
[0050] Fire extinguishing section 600 includes fire extinguishing board 201 , void 202 , and closure section 601 .
[0051] Fire extinguishing board 201 is provided with closure section 601 .
[0052] Closure section 601 is formed of a material different from that of fire extinguishing board 201 . Closure section 601 is formed of a material that melts under an environment of the fire extinguishing start temperature or above, and is attached to fire extinguishing board 201 . The material of closure section 601 is same as that of closure section 203 of Embodiment 1, and the description thereof is omitted.
[0053] Closure section 601 is provided in wall section 201 a that separates void 202 from the exterior in fire extinguishing section 600 . Closure section 601 has irregularity on side wall 601 a , and is engaged with wall section 201 a by the irregularity. When provided in wall section 201 a , closure section 601 seals void 202 from the exterior.
[0054] Under an environment of a temperature below the fire extinguishing start temperature, the state where closure section 601 is provided in fire extinguishing board 201 is maintained. Thus, the refrigerant having entered void 202 from circulation path 106 is output to circulation path 106 without being emitted to the exterior of fire extinguishing section 600 . In addition, under an environment of the fire extinguishing start temperature or above, closure section 601 is melted by heat. Thus, the refrigerant having entered void 202 from circulation path 106 is emitted out of fire extinguishing section 600 .
[0055] A predetermined pressure is exerted on closure section 601 by the refrigerant having entered void 202 , and therefore, closure section 601 is so provided in fire extinguishing board 201 as not to be dropped off from fire extinguishing board 201 by the pressure of the refrigerant under an environment of a temperature below the fire extinguishing start temperature.
<Fire Extinguishing Method>
[0056] A fire extinguishing method in Embodiment 2 of the present invention is described with reference to FIG. 6 .
[0057] Referring to FIG. 6 , closure section 601 is heated and melted by fire when fire occurs at device 301 , under an environment of the fire extinguishing start temperature or above. At this time, the protruding parts of the irregularity of side wall 601 a of closure section 601 are melted, and closure section 601 drops off from fire extinguishing board 201 , or a gap is defined between side wall 601 a and wall section 201 a . Accordingly, through the through hole defined after closure section 601 drops off, or through the through hole in the form of the gap defined between side wall 601 a and wall section 201 a , the refrigerant can be emitted out of void 202 .
[0058] It is to be noted that the other points of the fire extinguishing method in the present embodiment are same as in Embodiment 1, and the description thereof is omitted.
<Effect of the Present Embodiment>
[0059] According to the present invention, fire or the like can be surely extinguished by performing fire extinguishing without using a sensor to detect temperature changes.
[0060] In addition, according to the present embodiment, since the closure section is engaged by the irregularity with the wall section of the fire extinguishing board, it is possible to securely prevent the closure section from dropping off due to the shock and the pressure of the refrigerant applied to the in-vehicle fire extinguishing apparatus.
[0061] In addition, according to the present embodiment, the closure section and the fire extinguishing board are engaged with each other by the irregularity, and, under an environment of the fire extinguishing start temperature or above, the refrigerant can be emitted to the exterior by only melting the protruding part of the side wall of the closure section. Thus, the closure section can be melted with low energy, and fire can be extinguished at an early stage.
[0062] In addition, according to the present embodiment, when a pressure-regulating valve is provided in the fire extinguishing section, it is possible to prevent the closure section from being dropped off from the fire extinguishing board by the pressure of the refrigerant exerted on the closure section, under an environment of a temperature below the fire extinguishing start temperature.
Embodiment 3
Configuration of Fire Extinguishing Section
[0063] The configuration of fire extinguishing section 700 in Embodiment 3 of the present invention is described with reference to FIG. 7 . FIG. 7 is an enlarged sectional view of a main part of fire extinguishing section 700 in the present embodiment.
[0064] As compared with fire extinguishing section 104 according to Embodiment 1 illustrated in FIG. 2 and FIG. 3 , fire extinguishing section 700 illustrated in FIG. 7 includes closure section 701 in place of closure section 203 . It is to be noted that, in FIG. 7 , the same reference numerals are attached to the components same as those in FIG. 2 to FIG. 4 , and the descriptions thereof are omitted. In addition, the configuration of the in-vehicle fire extinguishing apparatus according to the embodiment of the present embodiment is same as that of FIG. 1 , and the description thereof is omitted.
[0065] Fire extinguishing section 700 includes fire extinguishing board 201 , void 202 , and closure section 701 .
[0066] Fire extinguishing board 201 is provided with closure section 701 .
[0067] Closure section 701 is formed of a material different from that of fire extinguishing board 201 . Closure section 701 is formed of a material that is melted by a temperature greater than the fire extinguishing start temperature, and closure section 701 is attached to fire extinguishing board 201 . The material of closure section 701 is same as that of closure section 203 of Embodiment 1, and the description thereof is omitted.
[0068] Closure section 701 is provided in wall section 201 a that separates void 202 from the exterior in fire extinguishing section 700 . As viewed in the thickness cross-section of wall section 201 a , closure section 701 has a form tapering from the exterior toward void 202 of fire extinguishing section 700 . When provided in wall section 201 a , closure section 701 seals void 202 from the exterior.
[0069] Under an environment of a temperature below the fire extinguishing start temperature, the state where closure section 701 is provided in fire extinguishing board 201 is maintained. Thus, the refrigerant having entered void 202 from circulation path 106 is output to circulation path 106 without being emitted to the exterior of fire extinguishing section 700 . In addition, under an environment of the fire extinguishing start temperature or above, closure section 701 is melted by heat. Thus, the refrigerant having entered void 202 from circulation path 106 is emitted out of fire extinguishing section 700 .
[0070] A predetermined pressure is exerted on closure section 701 by the refrigerant having entered void 202 , and therefore, closure section 701 is so provided in fire extinguishing board 201 as not to be dropped off from fire extinguishing board 201 by the pressure of the refrigerant under an environment of a temperature below the fire extinguishing start temperature.
[0071] It is to be noted that the other points of the fire extinguishing method in the present embodiment are same as in Embodiment 1, and the description thereof is omitted.
<Effect of the Present Embodiment>
[0072] According to the present invention, fire or the like can be surely extinguished by performing fire extinguishing without using a sensor to detect temperature changes.
[0073] In addition, according to the present embodiment, the closure section has a form tapering from the exterior toward the interior of the fire extinguishing section as viewed in the thickness cross-section of the wall section. Thus, since the size of the surface area contacting the refrigerant can be reduced, the influence of the pressure of the refrigerant can be minimized, and the area heated by fire when fire is caused can be increased. Thus, the closure section can be melted with low energy, and fire can be extinguished at an early stage.
[0074] In addition, according to the present embodiment, when a pressure-regulating valve is provided in the fire extinguishing section, it is possible to prevent the closure section from being dropped off from the fire extinguishing board by the pressure of the refrigerant exerted on the closure section, under an environment of a temperature below the fire extinguishing start temperature.
Embodiment 4
Configuration of Fire Extinguishing Section
[0075] The configuration of fire extinguishing section 800 in Embodiment 4 of the present invention is described with reference to FIG. 8 . FIG. 8 is an enlarged sectional view of a main part of fire extinguishing section 800 in the present embodiment.
[0076] As compared with fire extinguishing section 104 according to Embodiment 1 illustrated in FIG. 2 and FIG. 3 , fire extinguishing section 800 illustrated in FIG. 8 includes closure section 801 in place of closure section 203 . It is to be noted that, in FIG. 8 , the same reference numerals are attached to the components same as those in FIG. 2 to FIG. 4 , and the descriptions thereof are omitted. In addition, the configuration of the in-vehicle fire extinguishing apparatus according to the embodiment of the present embodiment is same as that of FIG. 1 , and the description thereof is omitted.
[0077] Fire extinguishing section 800 includes fire extinguishing board 201 , void 202 (omitted in FIG. 8 ), and closure section 801 .
[0078] Fire extinguishing board 201 is provided with closure section 801 .
[0079] Closure section 801 is formed of a material different from that of fire extinguishing board 201 . Closure section 801 is formed of a material that is melted by a temperature greater than the fire extinguishing start temperature, and closure section 801 is attached to fire extinguishing board 201 . The material of closure section 801 is same as that of closure section 203 of Embodiment 1, and the description thereof is omitted.
[0080] Closure section 801 is provided in wall section 201 a that separates void 202 from the exterior in fire extinguishing section 800 . In closure section 801 , screw thread 801 b is formed on side wall 801 a , and screw thread 801 b is threadedly engaged with wall section 201 a . When provided in wall section 201 a , closure section 801 seals void 202 from the exterior.
[0081] Under an environment of a temperature below the fire extinguishing start temperature, the state where closure section 801 is provided in fire extinguishing board 201 is maintained. Thus, the refrigerant having entered void 202 from circulation path 106 is output to circulation path 106 without being emitted to the exterior of fire extinguishing section 800 . In addition, under an environment of the fire extinguishing start temperature or above, closure section 801 is melted by heat. Thus, the refrigerant having entered void 202 from circulation path 106 is emitted out of fire extinguishing section 800 .
[0082] A predetermined pressure is exerted on closure section 801 by the refrigerant having entered void 202 , and therefore, closure section 801 is so provided in fire extinguishing board 201 as not to be dropped off from fire extinguishing board 201 by the pressure of the refrigerant under an environment of a temperature below the fire extinguishing start temperature.
<Fire Extinguishing Method>
[0083] A fire extinguishing method in Embodiment 4 of the present invention is described with reference to FIG. 8 .
[0084] Referring to FIG. 8 , closure section 801 is heated and melted by fire when fire occurs at device 301 , under an environment of the fire extinguishing start temperature or above. At this time, when screw thread 801 b of side wall 801 a is melted, closure section 801 is drops off from fire extinguishing board 201 , or a gap is defined between side wall 801 a and wall section 201 a . Accordingly, through the through hole defined after closure section 801 drops off, or through the through hole in the form of the gap defined between side wall 801 a and wall section 201 a , the refrigerant can be emitted out of void 202 .
[0085] It is to be noted that the other points of the fire extinguishing method in the present embodiment are same as in Embodiment 1, and the description thereof is omitted.
<Effect of the Present Embodiment>
[0086] According to the present invention, fire or the like can be surely extinguished by performing fire extinguishing without using a sensor to detect temperature changes.
[0087] In addition, according to the present embodiment, since the closure section is threadedly engaged with the fire extinguishing board, it is possible to securely prevent the closure section from dropping off due to the shock and the pressure of the refrigerant applied to the in-vehicle fire extinguishing apparatus.
[0088] In addition, according to the present embodiment, the refrigerant is emitted to the exterior when the screw thread of the side wall of the closure section is melted. Thus, the closure section can be melted with low energy, and fire can be extinguished at an early stage.
[0089] In addition, according to the present embodiment, when a pressure-regulating valve is provided in the fire extinguishing section, it is possible to prevent the closure section from being dropped off from the fire extinguishing board by the pressure of the refrigerant exerted on the closure section, under an environment of a temperature below the fire extinguishing start temperature.
Embodiment 5
Configuration of Fire Extinguishing Section
[0090] The configuration of fire extinguishing section 900 in Embodiment 5 of the present invention is described with reference to FIG. 9 . FIG. 9 is an enlarged sectional view of a main part of fire extinguishing section 900 in the present embodiment.
[0091] As compared with fire extinguishing section 104 according to Embodiment 1 illustrated in FIG. 2 and FIG. 3 , fire extinguishing section 900 illustrated in FIG. 9 includes closure section 901 in place of closure section 203 . It is to be noted that, in FIG. 9 , the same reference numerals are attached to the components same as those in FIG. 2 to FIG. 4 , and the descriptions thereof are omitted. In addition, the configuration of the in-vehicle fire extinguishing apparatus according to the embodiment of the present embodiment is same as that of FIG. 1 , and the description thereof is omitted.
[0092] Fire extinguishing section 900 includes fire extinguishing board 201 , void 202 , and closure section 901 .
[0093] Fire extinguishing board 201 is provided with closure section 901 .
[0094] Closure section 901 is formed of a material different from that of fire extinguishing board 201 . Closure section 901 is formed of a material that is melted by a temperature greater than the fire extinguishing start temperature, and closure section 901 is attached to fire extinguishing board 201 . The material of closure section 901 is same as that of closure section 203 of Embodiment 1, and the description thereof is omitted.
[0095] Closure section 901 is provided in wall section 201 a that separates void 202 from the exterior in fire extinguishing section 900 . As viewed in the thickness cross-section of wall section 201 a , closure section 901 has a form tapering from void 202 toward the exterior of fire extinguishing section 900 . When provided in wall section 201 a , closure section 901 seals void 202 from the exterior.
[0096] Under an environment of a temperature below the fire extinguishing start temperature, the state where closure section 901 is provided in fire extinguishing board 201 is maintained. Thus, the refrigerant having entered void 202 from circulation path 106 is output to circulation path 106 without being emitted to the exterior of fire extinguishing section 900 . In addition, under an environment of the fire extinguishing start temperature or above, closure section 901 is melted by heat. Thus, the refrigerant having entered void 202 from circulation path 106 is emitted out of fire extinguishing section 900 .
[0097] It is to be noted that the other points of the fire extinguishing method in the present embodiment are same as in Embodiment 1, and the description thereof is omitted.
<Effect of the Present Embodiment>
[0098] According to the present invention, fire or the like can be surely extinguished by performing fire extinguishing without using a sensor to detect temperature changes.
[0099] In addition, according to the present embodiment, the closure section has a form tapering from the interior toward the exterior of the fire extinguishing section as viewed in the thickness cross-section of the wall section. Thus, it is possible to prevent the closure section from dropping off from the fire extinguishing board when the pressure of the refrigerant is increased in the state where fire is not caused.
[0100] In addition, according to the present embodiment, when a pressure-regulating valve is provided in the fire extinguishing section, it is possible to prevent the closure section from being dropped off from the fire extinguishing board by the pressure of the refrigerant exerted on the closure section, under an environment of a temperature below the fire extinguishing start temperature.
<Modification Common to All Embodiments>
[0101] While the refrigerant is emitted to the exterior when the closure section is melted in the above-mentioned Embodiments 1 to 5, the present invention is not limited to this, and the refrigerant may be emitted to the exterior when the entirety of the fire extinguishing section is melted. In this case, the closure section is unnecessary.
[0102] In addition, while the fire extinguishing section is provided in the circulation path between the expansion valve and the evaporator in the above-mentioned Embodiment 1 to embodiment 5, the present invention is not limited to this, and the fire extinguishing section may be provided between the evaporator and the compressor.
[0103] In addition, while a plurality of the closure sections are provided in the above-mentioned Embodiments 1 to 5, the present invention is not limited to this, and the number of the closure section may be one.
[0104] This application is entitled to and claims the benefit of Japanese Patent Application No. 2012-068961 dated Mar. 26, 2012, the disclosure of which including the specification, drawings and abstract is incorporated herein by reference in its entirety.
INDUSTRIAL APPLICABILITY
[0105] The in-vehicle fire extinguishing apparatus according to the embodiments of the present invention is suitable for use in performing fire extinguishing by utilizing an air conditioning apparatus that heats or cools the vehicle interior.
REFERENCE SIGNS LIST
[0000]
100 In-vehicle fire extinguishing apparatus
101 Compressor
102 Condenser
103 Expansion valve
104 Fire extinguishing section
105 Evaporator
106 Circulation path
150 Air conditioning section | The present invention reliably extinguishes fires in devices that have exceeded the guaranteed temperature without the use of a sensor. An in-vehicle fire extinguisher ( 100 ) extinguishes fires using an air conditioner for heating or cooling the interior of a vehicle compartment. A coolant discharged from a compressor ( 101 ) is pumped into the compressor ( 101 ) through a circulation path ( 106 ) via a condenser ( 102 ), an expansion valve ( 103 ) and an evaporator ( 105 ). A fire extinguishing unit ( 104 ) is provided to the circulation path ( 106 ) between the expansion valve ( 103 ) and the compressor ( 101 ). When a device mounted in a vehicle exceeds the guaranteed temperature, the fire extinguishing unit ( 104 ) melts so that coolant pumped from the circulation path ( 106 ) is discharged to the exterior and extinguishes the device fire. | 0 |
This is a division of application Ser. No. 914,968 filed June 12, 1978, now U.S. Pat. No. 4,257,831.
BACKGROUND OF THE INVENTION
The invention relates to an apparatus for the continuous hardening of pump casings which may or may not have an inner plating and with or without modifying the core characteristics by subjecting the inner surface of the casing to the action of a flame hardening apparatus.
Armoured pump casings are mainly made from cast steel. Wearing plates are not provided on the inside of such pump casings and repairs are carried out by welding the casing.
The casing for the pump system is constructed by fitting a cast casing into an outer sheet metal shell, which is split and whose two shell parts are screwed together. This casing is less expensive, because it does not have the otherwise necessary static ribbing and casing base. However, the prime costs for such pump systems are considerably higher.
In the case of large pumps, which are for example used in wet dredgers the inside of the pump casing is lined with wearing plates, i.e. internal plating is provided. Steel having a C-content of 0.12 to 0.8% is generally used for this purpose. The thickness of the wearing plates is dependent on the degree of wear and is laid down by the dredger companies, varying between 10 and 40 mm. As they are not hardened the hardness of the wearing plates is max. 20 MRC. In the case of one shift operation the internal plating has to be replaced two or three times yearly. However, as a function of the hydraulic packing material this figure may be increased or decreased.
BRIEF SUMMARY OF THE INVENTION
The problem of the present invention is to provide an apparatus for flame hardening of pump casings, particularly those having an internal plating, so that the life of the thus treated pump casing is increased, even if it is exposed to high wear.
This problem is solved by the continuous hardening of pump casings by means of a flame hardening apparatus in which the core characteristics of the material may or may not be modified in which the horizontally positioned pump casing is moved past the flame hardening apparatus about its vertical axis and is simultaneously moved out of the horizontal position in such a way that the cooling water is removed via the already hardened inner wall surface.
According to the invention the apparatus for performing this process has a flame hardening apparatus with a flame hardening burner arranged in the inner area of the pump casing, a supporting disc arranged horizontally in a machine casing, which can be caused to rotate by means of a drive mechanism and which can be pivoted about the horizontal by a further drive mechanism, and retaining devices arranged on the supporting disc and receiving the pump casing.
The invention also provides a process for the continuous hardening of pump casings by means of a flame hardening apparatus, with or without modification to the core characteristics of the material, in which the flame hardening apparatus is moved past the inner wall of the horizontally arranged fixed pump casing and the latter is swung out of the horizontal position in such a way that the cooling water is removed over the already hardened inner surface.
According to the invention the apparatus has a flame hardening apparatus with a flame hardening burner arranged in the inner area of the pump casing and which can be moved in a circular path by means of a drive mechanism, a supporting disc arranged horizontally in a machine casing and pivotable about its horizontal plane by means of a further drive mechanism and retaining devices arranged on the supporting disc which receive the pump casing.
According to the invention the set problem is solved by the continuous hardening of pump casings by means of a flame hardening apparatus, with or without modification to the core characteristics of the material in which the flame hardening apparatus is moved upwards along one side of the inner wall of the vertically positioned pump casing from the lowest point to the highest point, is switched off, is returned to the lowest point and then after switching on again is moved along the other side up to the highest point.
The apparatus has a machine frame with devices for supporting the pump casing in the vertical position, two arm-like bearing supports spaced from one another on either side of the pump casing, a drivable shaft mounted in the same with a swivel arm fixed thereto and which carries on its free end the flame hardening apparatus with a flame hardening burner.
Further advantageous developments of the apparatus according to the invention can be gathered from the remaining subclaims. Of particular advantage is the development in which the retaining or swivel arms carrying the flame hardening apparatus are constructed so as to be automatically lengthwise adjustable because pump casings are not constructed in a symmetrical manner so that it is necessary that the flame hardening apparatus with the flame hardening burner is always moved past at a uniform distance from the inner wall surface of the pump casing.
The flame hardening procedure for the continuous surface hardening of the inner surface of pump casings with or without internal plating and the apparatus constructed for this ensure the completely satisfactory internal hardening of pump casings. Thus, the pump casings can be hardened from the inside because the flame hardening apparatus is moved slowly along the inner wall surface of the pump casing for the performance of the internal hardening through the rotary movement of the pump casing or with a fixed casing in the case of the flame hardening apparatus being moved along a circular path. This internal hardening makes the pump casing, through which abrasive materials are passed, wear-resistant, particularly for use in wet dredgers. Furthermore the service life of pump casings hardened in this way is much longer than that of the hitherto known pump casings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described hereinafter relative to nonlimitative embodiments and with reference to the attached drawings, wherein show:
FIG. 1 an apparatus with a rotating pump casing and with a fixed flame hardening burner viewed from above and with the upper pump casing cover partly removed.
FIG. 2 a side view of the apparatus of FIG. 1.
FIG. 3 a further embodiment of the apparatus with a fixed pump casing and with a flame hardening burner movable on a circular path corresponding to the arc radius of the pump casing viewed from above and with the pump casing cover partly removed.
FIG. 4 an embodiment of the apparatus with a vertical fixed pump casing and with a movable flame hardening burner in side view.
FIG. 5 the apparatus according to FIG. 4 partly in side view and partly in vertical section.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The apparatus for the surface hardening of the inner surface of pump casings shown in FIGS. 1 and 2 comprises a machine frame 10 having a horizontally positioned supporting disc 11 which by means of a swivel joint, such as e.g. a ball and socket joint or the like 12 is connected to the machine frame 10 in such a way that supporting disc 11 can move to all sides in the direction of the arrows X, X1 (of FIG. 2). The pivoting of supporting disc 11 out of its horizontal plane 14 takes place by means of a drive mechanism indicated at 15. In addition supporting disc 11 can be rotated about its vertical axis 18. Supporting disc 11 can be rotated by the drive mechanism 13. However, it is also possible to combine the drive mechanism 13 for the rotary driving of supporting disc 11 and the drive mechanism 15 for the disc movement into a single drive mechanism. Preferably supporting disc 11, rotatable about its vertical axis 18, is held on a bearing support 111 which is in operative connection with the drive mechanism 15 (FIG. 2).
On the top of supporting disc 11 retaining devices 19 are provided for the pump casing to be hardened. These retaining devices 19 are constructed as locking devices and may for example comprise clamping jaws so as to give the casings to be hardened an adequate hold, particularly during the rotation of the supporting disc 11.
The pump casing shown in FIGS. 1 to 5 is 100, its inner area 101 and its pressure connection 102, whilst its suction connection is indicated at 103.
For the surface hardening of the inner surface of a pump casing 100 the inner area 101 of casing 100 contains a flame hardening apparatus, comprising a flame hardening burner 20 fixed to the machine frame 10 and which is arranged in the inner area 101 of casing 100 in such a way that during the rotation of supporting disc 11 and consequently during the rotation of pump casing 100 the flames from the flame hardening burner 20 act on the inner wall of the casing.
The flame hardening burner 20 corresponds to the internal cross-sectional profile of pump casing 100 and preferably has a U-shaped or circular profile, as indicated in FIG. 5. The flame hardening burner 20 has peripherally distributed flame outlet openings.
The support and guidance of the flame hardening burner 20 in inner area 101 of pump casing 100 is effected by means of a vertical supporting member 16 fixed to machine frame 10 and whose upper end 16a is bent in U-shaped manner, whereby it has a horizontal portion 16b and a vertical portion 16c. The end of supporting member portion 16c which is parallel to the supporting member 16 and runs in the direction of machine frame 10 has a horizontal retaining arm 17, whose free end carries the flame hardening burner 20. The retaining arm 17 receives the supply lines V for the flame hardening burner 20. The flame outlet openings arranged on the periphery thereof are formed in such a way that the flames escape in the direction of arrow Y and act on the inner wall surface of pump casing 100. The dimensions of the flame hardening burner 20 are such that when the pump casing passes through the flame hardening apparatus burner 20 slowly moves through the inner area of casing 100. Retaining arm 17 also has the feedlines for the supply of cooling water.
On machine frame 10 is also provided a cooling mechanism 60 which supplies cooling water K for cooling the outer wall surface of pump casing 100. This cooling mechanism 60 comprises a hydraulic main having a configuration corresponding to that of the outer profile of pump casing 100 and which is provided with cooling water discharge nozzles directed onto the outer wall of casing 100.
Since for example in the case of single-acting centrifugal pumps in spiral casings the rotation axis of the impeller does not coincide with the central axis of the suction connection it is necessary for the length of the retaining arm 17 for the flame hardening burner 20 to be variable so as to ensure that on directing the flame hardening burner 20 onto the inner wall of pump casing 100 the same spacing is maintained if the supporting portion 16c of supporting member 16 which carries the retaining arm 17 is not arranged centrally with respect to pump casing 100. In order to bring about a length compensation of retaining arm 17 the latter comprises at least two, preferably telescopically extendable and retractable portions 17a, 17b. The extension or retraction of both arm portions 17a, 17b takes place in the direction of arrow X2 (FIG. 1). In order to bring about the automatic length compensation the larger retaining arm portion 17b has a compression spring, which is not shown in the drawing, which forces arm portion 17a into the necessary position. To maintain the correct spacing between the flame hardening burner 20 and the inner wall of pump casing 100 to be treated burner 20 can be provided with spacers which are not shown in the drawings. The possibility also exists of using a differently constructed mechanism for the automatic length adjustment of the retaining arm 17 which ensures the maintenance of the necessary constant spacing between flame hardening burner 20 and the inner wall of pump casing 100.
The apparatus for the surface hardening of the inner surface of pump casings shown in FIGS. 1 and 2 operates in the following manner. After fixing the pump casing 100 to be hardened to the supporting disc 11 flame hardening burner 20 is introduced into the inner area 101 of pump casing 100 either through the suction connection 103 of casing 100 or via the casing opening facing connection 103 for the passage of the drive shaft for the impeller by means of supporting disc member 16c. Supporting disc 11 is then rotated by means of drive mechanism 13 in the direction of arrow X3, so that the inner wall surface of pump casing 100 slowly passes flame hardening burner 20. To prevent any cooling water from entering the flame hardening area or the vicinity of not yet hardened wall portions of the pump casing, disc 11 with pump casing 100 arranged thereon is pivoted by means of drive mechanism 15 in such a way that the cooling water is removed from the flame hardening zone over already hardened inner wall areas of the casing to a point on the latter at which the cooling water can either be removed by suction or drained off, such as for example through the pressure connection or the suction connection, dependent on where the flame hardening burner 20 is introduced.
Whereas in the case of the apparatus according to FIGS. 1 and 2 pump casing 100 is slowly moved past a fixed flame hardening burner 20 in the embodiment shown in FIG. 3 burner 20 rotates, whilst pump casing 100 is fixed.
The apparatus for the surface hardening of the inner surface of pump casing shown in FIG. 3 also comprises machine frame 10 and supporting disc 11a connected to said frame by means of the swivel joint 25, said disc 11a also being provided with retaining devices 19 for pump casing 100. Supporting disc 11a is fixed, i.e. it is not rotated in the same way as supporting disc 11 in the apparatus according to FIGS. 1 and 2. However, like disc 11, disc 11a can be pivoted out of its horizontal plane 14 by means of drive mechanism 15. The flame hardening burner 20 arranged in the inner area 101 of pump casing 100 to be hardened is held on machine frame 10 by means of a bridge-like bearing support 31 and a vertical drive shaft 37, with the interpositioning of a swivel arm 36. The bridge-like bearing support 31 comprises vertical struts 32, 33 connected to machine frame 10 and which are interconnected by means of the horizontal strut 34 constructed as a supporting strut for a drive mechanism 35 with vertical drive shaft 37. Drive shaft 37 carries at its end the swivel arm 36, which again carries the flame hardening burner 20. Burner 20 is constructed in the same way as the burner described relative to FIGS. 1 and 2. A cooling mechanism 60 is once again connected to machine frame 10.
The apparatus shown in FIG. 3 functions as follows. After the pump casing 100 to be hardened has been fixed to the supporting disc 11a the flame hardening burner 20 is introduced into the inner area 101 of casing 100 and the drive mechanism 35 for drive shaft 37 or swivel arm 36 is put into operation, so that swivel arm 36 with burner 20 is moved in the direction of arrow X4 past the inner wall surface of pump casing 100. Preferably cooling mechanism 60 is arranged on a ring, which is not shown in the drawing and which is connected to the machine frame 10, whereby it is displaceable on said ring in order to always form a cooling zone on the outer surface of the casing 100 to be hardened wherever it is necessary.
Whereas in the case of the apparatus according to FIGS. 1 and 3 the pump casing to be hardened assumes a horizontal position during the hardening process FIGS. 4 and 5 show an embodiment of an apparatus for the surface hardening of the inner surface of pump casings in which the casing to be hardened assumes a vertical position. In the embodiment of FIGS. 4 and 5 the machine frame is again 10, whilst the retaining device for pump casing 100 is given the reference numeral 40. Machine frame 10 also has two spacedly arranged bearing supports 41, 42, which terminally carry a drive shaft 47 to which is fixed a swivel arm 46, which terminally carries the flame hardening burner 20. A drive mechanism 45 which performs the swivelling movement of swivel arm 46 with burner 20 is connected to drive shaft 47.
To prevent cooling water flowing into the flame hardening area or into the inner wall areas of the pump casing which have still not been hardened burner 20 is guided in the direction of arrow Z, Z1, Z2 (FIG. 4), its starting position being indicated by A. From starting position A flame hardening burner 20 is moved in the direction of arrow Z up to the upper end point B. During the movement of burner 20 in the direction of arrow Z the inner wall area of casing 100 which is passed by the flame hardening burner undergoes flame hardening. On reaching the upper position B the burner is rendered inoperative and is moved in the direction of arrow Z1 to the starting position A. From position A burner 20 is pivoted in the direction of arrow Z2 into the upper position B. During the passage in the direction of arrow Z2 the other inner wall area of the pump casing is hardened. The movement sequences of burner 20 are controlled by means of a drive mechanism 45 and a programme timing gear 50 connected therewith. The removal by suction of the cooling water from inner area 101 of pump casing 100 takes place in the direction of arrow Z3.
A corresponding control of the position of the pump casing 100 to be hardened also occurs with the apparatus of FIGS. 1 and 3. Here again drive mechanisms 13 and 15 are combined in a program timing gear which controls both the rotation of supporting disc 11 and the movement of the disc, as a function of the position of burner 20, so that a completely satisfactory removal of the cooling water from the flame hardening zone is ensured without said water reaching those areas of the inner wall of casing 100 which have not yet been hardened. In the apparatus of FIG. 3 the drive mechanism 35 for pivoting flame hardening burner 20 is combined with drive mechanism 15 for moving the disc in a common control mechanism. The control mechanisms can be constructed as programme timing gears.
The invention is not limited to the embodiments described and represented hereinbefore and various modifications can be made thereto without passing beyond the scope of the invention. | The invention relates to an apparatus for the continuous hardening of pump casings by means of flame hardening, with or without modifications to the core characteristics. As a result the life of the thus treated pump casing is considerably increased, even if it is exposed to a high degree of wear. This is achieved in that the horizontally positioned pump casing is moved past the flame hardening apparatus about a vertical axis and is simultaneously moved out of the horizontal position in such a way that the cooling water is removed over the already hardened inner wall surface. | 2 |
FIELD OF THE INVENTION
This invention relates to an automobile plenum airflow diverter. More particularly, the present invention relates a specifically sized and shaped apparatus that can be placed within the plenum of the intake manifold of an automobile to improve the air flow within the plenum this increases the air speed and air flow within the plenum. A replacement plenum is also disclosed that provides similar function that can be achieved by replacing a stock plenum. Even more specifically the apparatus is intended for the intake air plenum of a Porsche.
BACKGROUND OF THE INVENTION
For as long as gasoline powered motors have been around the need to increase the efficiency of these motors has been an issue. Many people and companies have spent money on the research and development on the design of products with the specific intent to improve fuel economy. One of the main areas to improve fuel economy is with the delivery of air to the combustion chamber. The more efficiently the air and or fuel can be delivered into the combustion chamber the more complete the burn, the higher the horsepower and ultimately the more efficient the engine. A number of patents have been issued that address changing how the air flows into the throttle body, through the plenum and into the cylinders of the engine.
One method of changing or adjusting the airflow through the plenum is covered in U.S. Pat. Nos. 4,210,107 and 4,977,866 issued to Shaffer and Wilkins respectively. These patents disclose using an adjustment plates or walls placed within the plenum of an engine. The location of the plates within the plenum can be externally adjusted to move the plates within the plenum whereby tuning the airflow as it passes through the plenum. While these devices allow the airflow through the plenum to be adjusted, they require manual adjustment to the plates within the plenum, are expensive to install, and include and adjustment component that allows for maladjustment of the plates or walls.
Another method of changing or adjusting the airflow through the plenum is covered in U.S. Pat. Nos. 6,776,146 and 6,776,400 issued to Ricart-Ugaz et al and Laneuvill respectively, these disclose the use of a flow obstructer that is placed in the path of air that enters the top of the carburetor or throttle body. These devices disturb the air entering the throat of the throttle body to create turbulent airflow. They further obstruct a portion of the air entering the throttle body and create a change in the flow of air into the engine. While they provide a diversion of the air entering the engine, the air flow entering the throttle body may be turbulent airflow. Placing these devices within the throttle body create pressure changes that may slow down the air as it enters the plenum.
A number of other patents disclose placing turbulent or swirling obstruction on top of the carburetor, throttle or within the plenum. These devices are disclosed in U.S. Pat. No. 4,015,574 issued to Hanff, U.S. Pat. No. 4,274,386 issued to Reyes, U.S. Pat. No. 4,463,742 issued to Williams, U.S. Pat. No. 4,474,163 issued to Linder et al, U.S. Pat. No. 4,962,642 issued to Kim, U.S. Pat. No. 6,752,124 issued to Chang and U.S. Pat. No. 6,796,296 issued to Kim. All these products introduce an obstructer into the airflow with an attempt to better mix the air and fuel. In the process of creating turbulent flow they also restrict the amount of air entering the engine and cause pressure changes with the plenum.
What is needed is a simple to install product that can be placed within a standard factory plenum or can replace a factory plenum that will smooth out the airflow within the plenum and allow more air to enter the engine and increase the horsepower from the engine. The proposed plenum airflow diverter provides this solution by providing simple component that can be placed within the plenum of a vehicle or where the plenum can be replaced to provide the features disclosed in this application. The proposed device satisfies these needs.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present plenum diverter is to provide a component that can be placed within a plenum to increase the airspeed and airflow through the plenum.
The present plenum diverter provides these features in a number of manners. One component can be placed in a “T” shaped plenum and diverts the airflow onto the plenum to be smoothly diverted into the output ports of the plenum. The shape of this components approximates the size and shape of the input and output ports of the plenum to reduce obstructions that can cause the air to slow down. The result of the components allows the standard “T” shaped plenum to operate more like a “Y” shaped plenum.
Another object of the plenum diverter insert is to provide the insert in both symmetric and non-symmetric shapes based upon the plenum where the insert is being used. These two or more variations allow a plethora of options to allow for variations that can accommodate a number of different shaped plenums.
A further object of the plenum diverter is to provide a replacement plenum that can be easily used to replace a “T” shaped plum and provide an increase in the airflow and air speed of the air through the plenum.
It is further an object of the plenum diverter to provide a plenum diverter that can accommodate the same, larger or various sizes of throttle bodies. If a larger throttle body is used with the plenum diverter a larger amount of air can enter the throttle body, the plenum and ultimately the engine. This will all result in higher air speed, higher airflow, greater horsepower and better fuel economy.
Various objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of prior art plenum that is currently being used.
FIG. 2 is a side view of the replacement plenum.
FIG. 3 is an isometric view of the replacement plenum.
FIG. 4 is a side cross sectional view of the plenum diverter insert placed inside the plenum shown in FIG. 1 .
FIG. 5 is an isometric view of the insert plenum diverter from FIG. 4 .
FIG. 6 is a side view of the insert plenum diverter from claim 4 showing the insert plenum diverter as symmetric.
FIG. 7 is a front view of the insert plenum diverter from claim 4 .
FIG. 8 is an isometric view of a non-symmetric insert plenum diverter.
FIG. 9 is a side view of the insert plenum diverter from claim 8 .
FIG. 10 is a front view of the insert plenum diverter from claim 8 .
FIG. 11 is a graph showing the change in horsepower from an engine before and after using the replacement plenum from FIG. 2
FIG. 12 is an isometric view of the replacement plenum showing the location of the replacement plenum in the intake manifold.
DETAILED DESCRIPTION
Referring to FIG. 1 there is shown side view of prior art plenum 10 that is currently being used. In this view a single the intake port 11 is shown where air 20 is brought into the plenum. The air exits the plenum through two exit ports 12 and 14 . Due to the “T” shape of the plenum some air that enters in the center of the input port will bounce off the far wall of the Plenum 115 and will cause some of the air to swirl or be turbulent as shown by item 22 . This air may exit the plenum 25 in a turbulent manner and slow the airflow through the plenum. Air that enters near the sides of the plenum 24 may make a smoother transition 26 to the output port(s).
To get a better understanding regarding where the plenum exists in an automobile, refer to FIG. 12 that shows an isometric view of the plenum 100 showing the location of the plenum in the intake manifold system. The plenum 100 is positioned between a throttle body 30 and intake manifolds or headers 40 and 45 . Air 50 enters the throttle body 30 after it is filtered. The throttle body 30 regulates the amount of air that is brought in to the throttle body using a simple flap valve, butterfly valve or similar regulating mechanism. The air 50 flows through the throttle boy and enters the plenum and then exits the plenum 52 and 54 where the air is sent into the intake manifolds or headers 40 and 45 . From within the headers the air is sent into each of the cylinders 60 to 65 of the engine. This figure shown the plenum with a single intake and air flow being diverted into a six separate cylinders, but an engine with as little as two or more than two cylinders is contemplated.
FIG. 2 is a side view of the replacement plenum. The plenum 100 in this figure is used in place of the standard plenum to provide superior air speed and airflow. From this view the airflow 112 is shown entering the input port 110 . As the air flows into the plenum the airflow is split with the apex of the diverter 114 . The apex is essentially a horizontal detail within the plenum that divides the airflow into to directions. The two separate air paths exit the plenum at 116 and 118 . The splitting of the airflow allows the stream of air to smoothly exit out of the plenum with a minimal disturbance and turbulence. The isometric view in FIG. 3 shows the appropriate size and shape of the replacement plenum and provides additional information regarding the unique attributes of the plenum.
FIG. 3 is an isometric view of the replacement plenum 100 where an inverted “T” shaped plenum is replaced with an inverted “Y” shaped plenum. The input port 110 is designed to accept a larger size 115 throttle body of 85 mm, while the standard plenum as shown in FIG. 1 , is designed for a 80 mm throttle valve. The larger throttle body allows a greater volume of air to enter the input port 110 of the plenum. The larger throttle body is an optional feature of the plenum diverter, but a variety of different size throttle bodies are contemplated including producing the replacement plenum with a variety of mounting holes or providing slots to allow for a variety of throttle bodies that can be changed without requiring the plenum to be replaced. In the preferred embodiment the output port(s) 120 are the same size 125 as original throttle body, but the plenum could be fabricated with output ports that are different in size than was used in the original equipment on the vehicle. The size of the output port on the original plenum is between 70 mm and 90 mm but can vary based upon the vehicle the replacement plenum is being installed into. While the preferred uses the dimensions disclosed, the inlet and outlet dimensions of the plenum can vary based upon the connections that are available on the vehicle. The replacement plenum includes the similar air, sensor and breather ports that are present on the original plenum installed on the vehicle. The locations of these ports are shown as item 130 , and 132 , but could be located in other places on the plenum. In the embodiment shown in FIG. 3 the plenum is completely replaced. Other embodiments are shown in FIGS. 4 to 10 where the plenum is not replaced, but a diverter is placed in the original factory plenum to accomplish a similar results.
In the preferred embodiment the replacement plenum is made from a metallic casting, but the replacement plenum can be made from any material that provides the desired function. The material may include but not be limited to plastics, metals or a combination thereof.
FIG. 4 is a side cross sectional view of the plenum diverter insert 140 placed inside the plenum 100 shown in FIG. 1 . The insert is a triangular shaped apparatus that can be placed within a standard plenum to accomplish similar results that can be achieved from the replacement plenum disclosed previously. In this figure the airflow 112 is shown entering the input port 110 . The air flowing into the plenum is split into two different directions by the apex 114 of the insert where the air stream exits the output ports of the plenum 116 and 118 . FIGS. 5 , 6 and 7 show various views of the diverter that can be placed into the plenum. These figures provide greater clarity of the design of the diverter. FIGS. 5 , 6 and 7 show the apex 114 of the diverter as essentially a straight surface the air stream flows onto and is split into two directions. The outside profile 145 of the diverter is appropriately designed to fit within the plenum without requiring modification of the plenum. The diverter is designed to approximate the cross section of the plenum, and areas 142 and 144 are semi-circular features that accomplish this design objective. The triangular shape starts at the apex and tapers down on the two ends to smooth the airflow out of the plenum. Recess(s) 150 is shown on the underside of the diverter to allow the diverter to be bonded into an existing plenum. Alternately, it is contemplated, that the diverter be screwed or fastened within the plenum using a variety of fastening means.
FIG. 7 shows that the profile of the diverter is circular to match the internal profile of the plenum. Dashed line 148 shown that the profile of the diverter could also be square or rectangular to match the profile of a different shaped plenum or manifold.
FIGS. 8 to 10 shows an alternate embodiment of the flow diverter where the diverter is not symmetrically shaped on both sides of the apex 114 . These figures also show a circular notch 160 on one side of the diverter that allows for the circulation of air to sensor or other parts of the vehicle that may be required based upon the plenum that is installed within the vehicle. A concave recess 152 is shown on the underside of the diverter to allow the diverter to be bonded into an existing plenum. In the preferred embodiment the diverter is made from a heat resistant plastic material, but the diverter can be made from any material that provides the desired function. The material may include but not be limited to plastics, metals or a combination thereof. FIG. 9 shows the underside of the diverter is concave to allow for placement of a bonding agent to attach the diverter into the plenum.
FIG. 11 is a graph showing the change in horsepower from an engine before and after using the replacement plenum from FIG. 2 . The X-axis of this graph shows the speed of the vehicle in Miles Per Hour, while the Y-axis shows the Horsepower of the vehicle. Two plots on the graph show the horsepower at the various speeds. The dashed line 185 shows that at a given speed the replacement plenum used 386.3 horsepower, while at the same speed the standard plenum used 416.5 horsepower. This graph is an example of the improvement that is achieved with the replacement plenum and or the diverter. These tests were measured using a Dynojet Model 2480 Dynamometer.
The air diverter(s) and replacement plenum is optimally designed for use in the six-cylinder motor that is used in a Porsche, but the air diverter and replacement plenum can be designed for use in a variety of vehicles and intake systems for other vehicles. In addition, the plenum is shown with a circular cross section for the air path, but other cross sectional air paths are contemplated including but not limited to square, rectangular, oval and others. The replacement plenum and the insert both provide a more consistent cross sectional area of the plenum that provides less restrictive and turbulent air flow, resulting in an increase of air flow rate, air speed and higher output from the engine.
Thus specific embodiments and applications for a replacement plenum and an airflow diverter plenum insert have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. | An airflow diverter and replacement air intake plenum is disclosed that provides an increase in the air speed and airflow within the intake plenum of an automobile. The increase is the result of providing appropriately sized and shaped apparatus to smooth out the airflow within the plenum and eliminate turbulence that increase pressure within the plenum and cause a restriction of air movement. The diverter is configured in a triangular shape to divert the air from a single input port into two output ports. The apparatus is ideally configured for use in a Porsche, but can be configured for other automobiles and engines. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/279,539, filed on Nov. 24, 2008, which application is a national phase entry under 35 U.S.C. §371 of International Application No. PCT/US06/42944 filed Nov. 3, 2006, which claims the benefit of U.S. Provisional Patent Application No. 60/733,988, filed Nov. 3, 2005. The disclosures of the aforesaid applications are hereby incorporated by reference herein.
FIELD OF THE INVENTION
[0002] Polymers with specialized properties for medical device coatings are described. These polymers are hydrolytically degradable and resorb within one year. These polymers are derived from monomer units which are relatively water soluble and it is this property that improves the polymers' resorption ability to within 1 year once hydrolytic degradation occurs. The polymers, nonetheless, still provide appropriately robust mechanical properties to function as medical device coatings. The polymers of the invention are based on modifications of the tyrosine-derived family of polyarylates.
BACKGROUND OF THE INVENTION
[0003] Diphenols, particularly those derived from tyrosine, are monomeric starting materials for biocompatible polycarbonates, polyiminocarbonates, polyarylates, polyurethanes, and the like. U.S. Pat. Nos. 5,099,060, 5,198,507, and 5,670,602 disclose amino acid-derived diphenol compounds useful in the preparation of polyarylates, polycarbonates and polyiminocarbonates. The polymers, for example those described in U.S. Pat. Nos. 4,980,449, 5,216,115, 5,658,995, 6,048,521, and 6,120,491, and U.S. patent application publication No. 2004/0254334, are useful as degradable polymers in general, and are particularly useful as tissue-compatible bioerodible materials for medical uses. The suitability of these polymers for this end use application is at least in part the result of their derivation from diphenols derived from the naturally-occurring amino acid L-tyrosine.
[0004] The polycarbonates in particular are strong, water-insoluble materials most suitable for use as structural implants. The L-tyrosine derived polyarylates described in U.S. Pat. No. 5,216,115, and the poly(alkylene oxide) block copolymers with these polyarylates disclosed in U.S. Pat. No. 5,658,995, feature protected carboxylic acid groups, and these polymers are limited in application because of their slow rate of degradation and significant hydrophobicity. The free acid forms of the polymers, described in U.S. Pat. No. 6,120,491 (“the '491 patent”), in which to varying degrees the ester protecting groups have been removed from the pendent carboxylic acid chains of the diphenols, are less hydrophobic and exhibit an increased degradation rate (i.e. backbone cleavage) compared to their counterparts with fully esterified carboxylic acid groups. Increasing the amount of pendant carboxylic acid diphenol contained within a particular polymer increases the hydrophilicity (water uptake) of the polymer; however, its relative complete resorption rate does not change significantly. This is because the mechanism of degradation—namely, backbone cleavage to successively smaller units containing diphenols with ester protected carboxylic acid groups—does not change the relative water solubility of the esterified monomeric units incorporated within the polymer chains, nor, in the case of the tyrosine-derived polyarylates, does it change the relative water solubility of the diacids with which they are condensed. Therefore, the introduction of an increasing fraction of free carboxylic acid side chains only increases the hydrophilicity of the polymer itself. It does not significantly impact the resorption rate of the ester diphenol fragments produced by polymer backbone degradation.
[0005] Hence, medical devices comprised of such materials will retain some significant portion of their mass for roughly the same time period as those polymers described in U.S. Pat. No. 5,099,060, which describes polymers with diphenol monomeric units that lack carboxylic acid side chains. Such polymers resorb completely only in time periods in excess of 1 year, and in many cases in closer to 2-2.5 years. The diphenol monomeric units of these polymers are significantly hydrophobic and have low water solubility.
[0006] The '491 patent describes polymers formed from a similar series of diphenol monomeric units but which contain repeating units of the same general diphenol monomers with both protected and unprotected carboxylic acid side chains. The '491 patent teaches that “the incorporation of pendent carboxylic acid groups within the polymer bulk has a dramatic and previously unrecognized accelerating effect on the rate of polymer backbone degradation and resorption both in vitro and in vivo.” However, the present inventors have surprisingly found that incorporating some fraction of diphenol monomers with pendant carboxylic acid groups into the polymer does not accelerate overall resorption, because the monomers with protected carboxylic acid groups remain too hydrophobic for resorption on desirable time scales. For example, a polymer incorporating 10% pendant carboxylic acid side chain will degrade (by backbone cleavage) at a faster rate than one containing no pendant carboxylic acid side chains, and some resorption will occur, but this resorption is due to the water solubility of the diphenol monomers containing the pendant carboxylic acid groups. Once this monomer is resorbed, the remaining polymer, albeit one of smaller chain length, contains the protected carboxylic acid side chain monomers which are hydrophobic and resorb at a very slow rate. Incorporating a high fraction of pendant carboxylic acid side chain monomer (e.g., 50% of the diphenol monomer content of the polymer) essentially creates a water-soluble polymer that solubilizes and undergoes degradation until the polymer chain fragments that are enriched in protected pendant carboxylic acid groups precipitate out of solution. The preferred protected monomers in the '491 patent are actually the most hydrophobic and therefore the slowest to resorb, i.e. the ethyl, butyl, hexyl, and octyl esters.
[0007] Complete, or nearly complete, polymer resorption (e.g., at least 90%, 95%, 96%. 97%. 98%, 99%, 99.5%, or 100%) is important in the use of “biodegradable” polymers in medical devices. Biodegradable and resorbable polymers are primarily used to deliver drugs for a finite period of time or to serve some other temporary purpose, such as to provide a biocompatible surface, enhanced tissue growth, or extra strength during implantation. Polymers that do not completely resorb leave remnants that can cause anything from minor inflammation and pain to excess scarring, and in the case of cardiovascular implants, such remnants can cause thrombosis and possibly patient death.
SUMMARY OF THE INVENTION
[0008] The invention provides polymers with specialized properties, making them particularly suitable for coatings on implanted medical devices, for forming films for use with medical devices, and other uses requiring the short- or defined-term presence of a polymer matrix. The polymers of the invention are hydrolytically degradable and are resorbed by the body within one year. These polymers are derived from monomer units which are relatively water-soluble and it is this property that improves the polymers' resorption time to within 1 year once hydrolytic degradation begins. The polymers nonetheless exhibit sufficiently robust mechanical properties to function as medical device coatings. The polymers of the invention are based on modifications of the tyrosine-derived family of polyarylates.
[0009] The need for polymers that resorb within one year (or such lesser times as may be desired), while retaining useful properties (e.g., at least 1 week of drug elution, biocompatibility, and spray coating capability), is met by the present invention. It has now been found that it is possible to effect better resorption by increasing the water solubility of one or more of the component parts of the diphenol or diacid monomer units of the polymer. Thus, the present invention makes it possible to modulate the rate of resorption without compromising the drug release rate or other physical properties optimized for the end use application, by choosing components having increased water solubility and/or or increased hydrolysis rates in vivo. Certain polymers of the invention can, for example, release a drug over at least a 5 day period.
[0010] The present invention also makes it possible to create resorbable polymers with pendant carboxylic acid groups, which modulates the hydrophilicity of the polymer as well as the time over which the polymer properties remain intact. This provides a wide variety of drug release capabilities, so that the polymer can be adapted for hydrophobic and hydrophilic drugs. This is a significant improvement over conventional medical polymers such as poly(lactic acid), poly(glycolic acid), polycaprolactone, and the phenolic polyarylates and polycarbonates exemplified in U.S. Pat. No. 6,120,491. This invention allows independent optimization of the useful properties of the polymers, and significantly improves upon the versatility and utility of the phenolic polymer systems known in the art, particularly phenolic polycarbonates, polyarylates, and poly(iminocarbonates), and poly(alkylene oxide) copolymers thereof.
[0011] The polymers of the present invention have many uses and may be formed into a variety of products, including but not limited to implantable medical devices with desired lifetimes of less than one year (e.g., adhesion barriers and surgical meshes to aid wound healing), incorporation into implantable medical devices, and combination with a quantity of a biologically or pharmaceutically active compound sufficient for effective site-specific or systemic drug delivery. See, for example, Gutowska et al., J. Biomater. Res., 29, 811-21 (1995) and Hoffman, J. Controlled Release, 6, 297-305 (1987). A biologically or pharmaceutically active compound may be physically admixed with, embedded in or dispersed in a polymer of the invention, or the polymer may be applied as an overcoating of another polymer-containing drug layer, where such overcoating delays or slows drug release. In other uses and products, the polymer is in the form of a sheet or a coating applied to an implantable medical device, such as a hernia repair mesh, a stent, or a barrier layer for the prevention of surgical adhesions (see, e.g., Urry et al., Mat. Res. Soc. Symp. Proc., 292, 253-64 (1993).
[0012] Another aspect of the present invention provides a method for site-specific or systemic drug delivery, by implanting in the body of a patient in need thereof an implantable drug delivery device containing a therapeutically effective amount of a biologically or pharmaceutically active compound, in a matrix of (or coated with) a polymer of the present invention. Yet another aspect of the present invention provides a method for preventing the formation of adhesions between injured or surgically repaired tissues, by inserting as a barrier between the injured tissues a sheet or coating comprising a polymer of the present invention.
BRIEF DESCRIPTION OF THE FIGURES
[0013] FIG. 1 shows the degradation over time of polymers of the invention.
[0014] FIG. 2 shows the degradation over time of polymers of the invention.
[0015] FIG. 3 shows the degradation over time of polymers of the invention.
[0016] FIG. 4 shows the degradation over time of polymers of the invention.
[0017] FIG. 5 shows the degradation over time of polymers of the invention.
[0018] FIG. 6 shows the degradation over time of polymers of the invention.
[0019] FIG. 7 shows the degradation over time of polymers of the invention.
[0020] FIG. 8 shows the degradation over time of polymers of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] As used herein, DTE refers to the diphenol monomer desaminotyrosyl-tyrosine ethyl ester; DTBn is the diphenol monomer desaminotyrosyl-tyrosine benzyl ester; DT is the diphenol monomer desaminotyrosyl-tyrosine with a free carboxylic acid. Other diphenol monomers can be named using a similar system. P22 is a polymer produced by condensation of DTE and succinic acid. P22-10, P22-15, P22-20, etc., represent polymers produced by condensation of a mixture of DTE and the indicated percentage of DT (i.e., 10, and 20% DT) with succinic acid. See U.S. patent application publication No. 2004/0254334 for further explanation and examples of the nomenclature of these phenolic polymers.
[0022] The invention provides diphenol monmer units having structure
[0000]
[0000] wherein m is 0, 1, or 2; n is 0 to 4, and Y is selected from the group consisting of C 1 -C 18 alkylamino, —NHCH 2 CO 2 R′, —NH(CH 2 ) q OR′, —NH(CH 2 CH 2 O) p R′, —NH(CH 2 CH 2 CH 2 O) p R′,
[0000]
[0000] where q is 0 to 4, p is 1 to 5000, and R′ is selected from the group consisting of H, C 1 -C 8 alkyl, C 2 -C 8 alkenyl, C 8 -C 14 alkylaryl, benzyl, and substituted benzyl. As used herein, the terms alkyl and alkenyl refer to branched- or straight-chain alkyl and alkenyl groups. The term aryl refers to phenyl and naphthyl groups which may be substituted or unsubstituted with halogen, methoxy, alkyl, and the like. The term alkylaryl does not refer to aryl groups having alkyl substituents; it refers to alkyl groups having an aryl substituent. Substituted benzyl refers to benzyl groups substituted with one or more halogens, methoxy groups, nitro groups, alkyl groups, and the like. Substituted benzyl groups known in the art to be suitable for use as protecting groups for ethers and esters are included, including but not limited to 4-methoxybenzyl, 2-methoxybenzyl, 2,4-dimethoxybenzyl, and 2-nitrobenzyl groups.
[0023] The invention also provides diphenol monomer units having structure
[0000]
[0000] wherein n is 0 to 4; and Y is selected from the group consisting of C 1 -C 18 alkylamino, —NHCH 2 CO 2 R′, —NH(CH 2 ) q OR′, —NH(CH 2 CH 2 O) p R′, —NH(CH 2 CH 2 CH 2 O) p R′,
[0000]
[0000] where q is 0 to 4, p is 1-5000 and R′ is selected from the group consisting of H, C 1 -C 8 alkyl, C 2 -C 8 alkenyl, C 8 -C 14 alkylaryl, benzyl, and substituted benzyl. In preferred embodiments, Y is NHCH 2 CO 2 R′.
[0024] The invention also provides diphenol monomer units having structure
[0000]
[0025] wherein m is 0, 1, or 2; and R′ is selected from the group, consisting of H, C 1 -C 18 alkyl, C 2 -C 18 alkenyl, C 8 -C 18 alkylaryl, benzyl, and substituted benzyl.
[0026] Through co-polymerization of the diphenol monomer units described above with phosgene, cyanogen bromide, or an appropriate diacid, by methods known in the art, the invention provides polymers comprising monomer units having formula
[0000]
[0000] wherein Y is OMe or OEt. In these polymers, m, n, and Y and R′ are as defined above, and A is selected from the group consisting of —CO—, —C(—NH)—, and —CO—X—CO—. In these polymers, X is selected from the group consisting of C 1 -C 18 alkylene, C 1 -C 18 alkenylene, divalent C 6 -C 10 arylene, divalent C 7 -C 18 alkylaryl, CH 2 OCH 2 , CH 2 O (CH 2 CH 2 O)SCH 2 , (CH 2 ) r CO 2 (CH 2 CH 2 CH 2 O) s CO(CH 2 ) r , and (CH 2 ) r CO 2 (CH 2 CH 2 O) s CO(CH 2 ) r , where r is 2 to 4 and s is 1 to 5000. In specific embodiments of the polymers of the invention, Y is preferably NHCH 2 CO 2 R′.
[0027] In certain embodiments, the polymers of the invention consist essentially of monomer units having formula
[0000]
[0000] where m, n, A and Y are as defined above.
[0028] In certain embodiments, the polymers of the invention as described above further comprising monomer units independently having formula
[0000]
[0000] wherein m, n, and A are as defined in claim 5 , and Y is OH or O-benzyl.
[0029] In preferred embodiments of these polymers, A is —CO—X—CO—, and between 0.1% and 99.9% of the X moieties are (CH 2 ) r CO 2 (CH 2 CH 2 O)SCO(CH 2 ), and/or (CH 2 ) r CO 2 (CH 2 CH 2 CH 2 O) s CO(CH 2 ) r . The range is preferably from about 1% to about 99%, more preferably from about 10% to about 80%. Most preferably, from about 20% to about 50% of the X moieties are (CH 2 ) r CO 2 (CH 2 CH 2 O) s CO(CH 2 ) r and/or (CH 2 ) r CO 2 (CH 2 CH 2 CH 2 O) s CO(CH 2 ) r .
[0030] In certain preferred embodiments, between about 1% and 50% of the monomer units have formula
[0000]
[0000] wherein Y is OH or O-benzyl. The range is more preferably from about 5% to about 40%, and most preferably from about 10% to about 30%.
[0031] Particularly preferred are polymers wherein A is —CO—X—X—CO—and X is CH 2 —O—(CH 2 CH 2 O)SCH 2 , with s being 0 to 200. Also provided are polymers comprising monomer units having formula
[0000]
[0000] wherein Y is OMe or OEt, A is selected from the group consisting of —CO—, —C(—NH)—, and —CO—X—CO—, and X is selected from the group consisting of CH 2 CH 2 , CH 2 CH 2 CH 2 , and CH 2 —O—(CH 2 CH 2 O) s CH 2 , and s is 0 to 200.
[0032] Polymers of the present invention may be formed by reaction of the diphenol monomer units of the invention with a diacid or with phosgene, thereby forming polyarylates and polycarbonates respectively. A schematic diagram of the reaction of the diphenol monomer DTE with a diacid is shown in Scheme 1 below.
[0000]
[0033] The compounds of the invention are those where the “starting” moieties designated as positions 1-4 below are replaced by one or more moieties that are more hydrophilic or more water-soluble, as illustrated in Tables 1 and 2 below.
[0000]
[0034] The polymers of the invention thus have at least one of any one of positions 1-4 changed, but can also have 2 positions, 3 positions or all four positions changed. Any permutation of changes to the 4 positions is contemplated, provided that at least one change is made and that at least one change to a moiety make it more soluble than its corresponding starting moiety. In the case of the ester position (position 3), the change may introduce a better leaving group than ethanol. Hence, in accordance with the invention, at least one moiety at one of the positions is more water soluble than its starting moiety; at position 3 the moiety may also be a better leaving group than ethanol, or otherwise be more sensitive to hydrolysis under the conditions of use. By way of example, amides can be more sensitive to hydrolysis in vivo than ethyl esters, due to the action of proteases.
[0035] The starting moieties are as follows: position 1, tyrosine (T); position 2, desaminotyrosine (D), position 3, ethyl ester (E); position 4, succinate (S or succinate). It is convenient to name the polymer families according to the four positions so that the “starting polymer” with no changes of moieties is DTES or DTE succinate (note this is distinct from DTE, when DTE refers to the diphenol monomeric unit). Either single letters or moiety names are used. Hence examples of polymer families include BTE glutarate, DTM glutarate, DTM succinate and the like. The single letters for each moiety as used herein are shown in Tables 1 and 2. In Table 1, the bold T is used as a shorthand to represent the remainder of the molecule.
[0036] The preferred polymer families of the invention are provided in Table 3 below and do not include all the possible permutations that occur from combining the all four positions. However, all such permutations are contemplated by the invention.
[0037] The polymers of the present invention preferably have from 0.1 to 99.9% diphenol monomer DT or from 0.1 to 99.9% PEG diacid to promote the degradation process. The use of either or both methods, i.e. incorporation of DT and/or a PEG diacid (see examples in table below), is within the scope of the invention, and can be used with any of the polymer families of the invention.
[0000]
TABLE 1
DTE
Chemical Name
Succimate
(Abbrc for polymer
See
water
family)
Changes
solubitily
Ethyl ester (E)
Site 3: none
Methyl ester (M)
3
Propyl amide
3
Glycine amide methyl ester
3
2-methoxyethyl amide
3
3-methoxypropyl amide
3
Glycine amide benzyl ester
3
Glycine amide
3
Glucose amine amide
3
PEG amide (n = 1-5000)
3
PEG ether (n = 1=5000)
3
Tyrosine (T)
Site 1: none
0.45 mg/mL
Hydroxyphenyl glycine
1
5
[0000]
TABLE 2
Polymer
Site
Water
Solubility
Basic Elements
Change
Solubility
Difference
Succinic acid
0
76
9
Glutaric acid
4
640
9
PEG diacid at .01-99% (moderate PEG, n = 1-500)
4
Water Soluble
Cleaner than 8 deposites beninium of PEG intergrated in breabeno
Diglycolic acid
4
Water soluble
Greater than 10
bis(carboxymethyl) PEG (N = 250-000)
4
Water soluble
Greater than 10
DAT
0
1.60
4-hydroxy benzoic acid
2
8
4
2-hydroxy phenylmethic acid
2
3-hydroxy benzaic acid
2
Salicyclic acid
[0000]
TABLE 3
Polymer Family
(includes all free
acid veralan)
BTE gluturate
DTM gluturate
DT Propylamide gluturate
DT Glycinamide methyl ester gluturate
BTE Succine
BTM succinate
BTM succinate PEG
BTM succinate PEG
DTM succinate PEG
DT propyl amide succinate
DT glucoamine succinate
DT glucoamine gluturate
DT PEG amide succinate
DT PEG amide gluturate
[0038] Methods for preparing the diphenol monomers are known in the art, for example as disclosed in U.S. Pat. Nos. 5,587,507 and 5,670,602. Methods for preparing polymers with DT content are disclosed in U.S. application publication 2004/0254334.
[0039] The polymers of the present invention having pendent carboxylic acid groups may be prepared by the palladium-catalyzed hydrogenolysis of corresponding polymers having pendant benzyl carboxylate groups as describe in the '491 patent. Any other method that allows for the selective deprotection of a pendant carboxylate group is suitable for use in the preparation of the carboxylate-containing polymers of the present invention.
[0040] The polymers of the present invention can find application in areas where both solid materials and solvent-soluble materials are commonly employed. Such application include polymeric scaffolds in tissue engineering applications and medical implant applications, including the use of the polycarbonates and polyarylates of the present invention to form shaped articles such as vascular grafts and stents, drug eluting stents, bone plates, sutures, implantable sensors, barriers for surgical adhesion prevention, implantable drug delivery devices, scaffolds for tissue regeneration, and other therapeutic agent articles that decompose harmlessly within a known period of time.
[0041] Controlled drug delivery systems may be prepared, in which a biologically or pharmaceutically active agent is physically embedded or dispersed within a polymeric matrix or physically admixed with a polycarbonate or polyarylate of the present invention, or it could be covalently attached to the pendant carboxylic acid.
[0042] Examples of biologically or pharmaceutically active compounds suitable for use with the present invention include non-steroidal anti-inflammatories such as naproxen, ketoprofen, ibuprofen; anesthetics such as licodaine, bupivacaine, and mepivacaine; paclitaxel, 5-fluorouracil; antimicrobials such as triclosan, chlorhexidine, rifampin, minocycline; keflex; acyclovir, cephradine, malphalen, procaine, ephedrine, adriamycin, daunomycin, plumbagin, atropine, quinine, digoxin, quinidine, biologically active peptides, chlorin e6, cephradine, cephalothin, cis-hydroxy-L-proline, melphalan, penicillin V, aspirin, nicotinic acid, chemodeoxycholic acid, chlorambucil, and the like. The compounds are covalently bonded to the polycarbonate or polyarylate copolymer by methods well understood by those of ordinary skill in the art. Drug delivery compounds may also be formed by physically blending the biologically or pharmaceutically active compound to be delivered with the polymers of the present invention having pendent carboxylic acid groups, using conventional techniques well-known to those of ordinary skill in the art.
[0043] Detailed chemical procedures for the attachment of various drugs and ligands to polymer bound free carboxylic acid groups have been described in the literature. See, for example, Nathan et al., Bio. Cong. Chem., 4, 54-62 (1993).
[0044] Biologically active compounds, for purposes of the present invention, are additionally defined as including cell attachment mediators, biologically active ligands and the like.
[0045] Processability of the polymers is generally as described in the '491 patent.
[0046] It will be appreciated by those skilled in the art that various omissions, additions and modifications may be made to the invention described above without departing from the scope of the invention, and all such modifications and changes are intended to fall within the scope of the invention, as defined by the appended claims. All references, patents, patent applications or other documents cited are herein incorporated by reference in their entirety.
EXPERIMENTAL
Degradation Study Protocol
[0047] Molecular weight (MW) profile: For monitoring MW decrease as a function of time, polymer films, or meshes coated with polymer, with approximate dimensions 1×1×0.01 cm, were incubated with 0.01 M PBS or 0.01 M PBS with Tween20 (50 to 100 mL) at 37° C. without shaking. At each time point, polymer samples were dissolved in 5 mL of DMF containing 0.1% TFA. The solutions were filtered through 0.45μ Teflon™ syringe-mountable tilters and transferred to analysis vials for analysis by gel permeation chromatography (GPC).
[0048] Mass loss profile: For mass loss analysis, films or meshes coated with polymer were incubated with 0.01 M PBS or 0.01 M PBS with Tween20 (50 to 100 mL) at 37° C. The buffer in the vials was changed at periodic intervals and analyzed for soluble degrading components. At each time point, 1-2 mL buffer from three small vials was filtered through 0.45μ Teflon™ syringe-mountable filters and transferred to analysis vials for analysis by reversed phase HPLC. Alternately, the devices were washed, dried and weighed (final weight) and the mass loss determined by subtracting the final weight from the original weight.
Polymer Synthesis
[0049] DTE (17.85 g), diglycolic acid (6.7 g) and DPTS catalyst (5.88 g) were added to 75 mL methylene chloride. After stirring for 30 minutes, diisopropylcarbodiimide (20 g) was added and the mixture stirred for 24 hours. The polymer formed was isolated by precipitation into 2-propanol. The polymer was purified by three precipitations from methylene chloride/isopropanol to produce the polymer P(DTE diglycolate) in about 65% yield. MW=40 to 75000.
Results
[0050] FIG. 1 shows molecular weight (MW) retention as a function of time for various members of the DTE succinate family with DT content ranging from 10-25% of the diphenol content. Very little difference in the degradation times (backbone cleavage) is evident.
[0051] FIG. 2 shows the mass loss of various members of the DTE succinate family with DT ranging from 10-25% of the diphenol content. The mass loss slows as function of time because the DT is gone.
[0052] FIG. 3 shows the mass loss of 10% DT/DTE succinate at 37° C. and 50° C. Mass loss slows down (curve evens out) as all DT is expended from the polymer.
[0053] FIGS. 4-8 show the rate of degradation of various polymers of the invention, as measured by the decrease in molecular weight over time.
[0054] The table below shows the average molecular weight (MW) and composition of residual fragments of polymers within the DT-DTE succinate family of polymers at various times during in vitro incubation. The residual fragments are analyzed by liquid chromatography-mass spectrometry and relative quantities of peaks for each compound are reported. No indicates that the compound corresponding to that peak was not detectable. The relative total mass is found by the sum of the peak areas for a given compound. From this it is evident that the DT-containing fragments peaks 1 and 4 represent very little of the remaining mass. Peak 8 also contains DT but with twice the amount of DTE-succinate. DTE-suc is DTE-succinate.
[0055] Virtually no DT-containing fragments remain at the time points noted and time to total resorption for all of the polymers within the DTE succinate family will be equivalent, because the remaining insoluble fraction in each polymer is chemically equivalent.
[0000]
Sample
Peak 1
Peak 2
Peak 3
Peak 4
Peak 5
Peak 6
Peak 7
Peak 8
Peak 9
P22-10
DT
DTE
No
DTE-
No
DTE-
DTE-suc-
DTE-suc-
DTE-suc-
MW = 3000
(1.67)
(0.29)
suc-DT
suc-DTE
DTE-suc-
DTE-suc-
DTE-suc-
(6 months)
(0.68)
(6.1)
DT (2.8)
DTE
DTE-suc-
(10)
DTE (9.5)
P22-12.5
No
DTE
No
DTE-
No
DTE-
DTE-suc-
DTE-suc-
DTE-suc-
MW = 2000
(0.037)
(2.33)
suc-DT
suc-DTE
DTE-suc-
DTE-suc-
DTE-suc-
(6 months)
(0.44)
(10)
DT (4.5)
DTE
DTE-suc-
(8.6)
DTE (6.9)
P22-15
DT
DTE
No
DTE-
No
DTE-
DTE-suc-
DTE-suc-
DTE-suc-
MW = 3000
(0.22)
(0.9)
suc-DT
suc-DTE
DTE-suc-
DTE-suc-
DTE-suc-
(4 months)
(0.4)
(8.7)
DT (2.66)
DTE
DTE-suc-
(10)
DTE (6.6)
P22-17.5
No
DTE
No
DTE-
No
DTE-
DTE-suc-
DTE-suc-
DTE-suc-
MW = 3700
(0.41)
(0.1)
suc-DT
suc-DTE
DTE-suc-
DTE-suc-
DTE-suc-
(3.5 months)
(0.39)
(4.58)
DT (2.1)
DTE
DTE-suc-
(7.2)
DTE (10)
PTT-20
DT
DTE
No
DTE-
No
DTE-
DTE-suc-
DTE-suc-
DTE-suc-
MW = 3600
(0.07)
(0.2)
suc-DT
suc-DTE
DTE-suc-
DTE-suc-
DTE-suc-
(5 months)
(0.28)
(6.2)
DT (1.6)
DTE
DTE-suc-
(10)
DTE (7.7)
[0056] For P(DTE diglycolate) incubated at 50° C. for 10 days in PBS buffer, the degradation results were as follows:
[0000]
MW (avg.) of
MW of residual
residual solid
solid
Initial MW
at 5 days
at 10 days
Solid: 25,000 kD
Solid: 7,000 kD
No solid remaining
Buffer: none
Buffer: DTE
Sample completely
resorbed
Buffer: DTE | The invention provides biocompatible resorbable polymers, comprising monomer units having formula (I), formula (II), formula (III) or formula (IV). The polymers degrade over time when implanted in the body, and are useful as components of implantable medical devices. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the field of papermaking, and, in particular, to an improved papermaking process utilizing hydrophobic dispersion polymers to increase retention of fibers onto the paper sheet.
2. Description of the Prior Art
In the manufacture of paper an aqueous cellulosic suspension or slurry is formed into a paper sheet. The cellulosic slurry is generally diluted to a consistency (percent dry weight of solids in the slurry) of less than 1 percent, and often below 0.5 percent, ahead of the paper machine, while the finished sheet must have less than 6 weight percent water. Hence, the dewatering aspects of papermaking are extremely important to the efficiency and cost of the manufacture.
An important aspect of papermaking is retention of furnish components on and within the fiber mat being formed during papermaking. A papermaking furnish contains particles that range in size from about the 2 to 3 millimeter size of cellulosic fibers to fillers measuring only a few microns. Within this range are cellulosic fines, mineral fillers (employed to increase opacity, brightness and other paper characteristics) and other small particles that generally, without the inclusion of one or more retention aids, would pass through the spaces (pores) between the cellulosic fibers in the fiber mat being formed.
One method of improving the retention of cellulosic fines, mineral fillers and other furnish components on the fiber mat is the use of a coagulant/flocculant system, added ahead of the paper machine. In such a system there is first added to the furnish a coagulant, for instance a low molecular weight cationic synthetic polymer or a cationic starch, which coagulant generally reduces the negative surface charges present on the particles in the furnish, particularly cellulosic fines and mineral fillers, and thereby agglomerates such particles. The coagulant is followed by the addition of a flocculent. The flocculent is generally a high molecular weight anionic synthetic polymer which bridges the particles and/or agglomerates, from one surface to another, binding the particles into large agglomerates. The presence of such large agglomerates in the furnish increases retention. The agglomerates are filtered out of the water onto the fiber web, where unagglomerated particles otherwise would to a great extent pass.
One system employed to provide an improved combination of retention and dewatering is described in U.S. Pat. Nos. 4,753,710 and 4,913,775, inventors Langley et al., issued respectively Jun. 28, 1988 and Apr. 3, 1990, the disclosures of which are incorporated herein by reference. In brief, such method adds to the aqueous cellulosic papermaking suspension first a high molecular weight linear cationic polymer before shearing the suspension, followed by the addition of bentonite after shearing. The shearing generally is provided by one or more of the cleaning, mixing and pumping stages of the papermaking process, and the shearing breaks down the large flocs formed by the high molecular weight polymer into microflocs, and further agglomeration then ensues with the addition of the bentonite clay particles.
Another system uses the combination of cationic starch followed by colloidal silica to increase the amount of material retained on the web by charge neutralization and adsorption of smaller agglomerates. This system is described in U.S. Pat. No. 4,388,150, inventors Sunden et all, issued Jun. 14, 1983.
Greater retention of fines and fillers permits a reduction in the cellulosic fiber content of the paper being formed. As pulps of less quality are employed to reduce papermaking costs, the retention aspect of papermaking becomes more important because the fines content of such lower quality pulps is generally greater than that of pulps of higher quality.
Greater retention of fines, fillers and other slurry components reduces the amount of such substances lost to the white water and hence reduces the amount of material waste, the cost of waste disposal and the adverse environmental effects therefrom.
As described in the Langley patents, paper or paper board is generally made from a suspension or slurry of cellulosic material in an aqueous medium, which slurry is subjected to one or more shear stages, which stages generally are a cleaning stage, a mixing stage and a pumping stage, and thereafter the suspension is drained to form a sheet, which sheet is then dried to the desired, and generally low, water concentration. As disclosed in these patents, the cationic polymer generally has a molecular weight of at least 500,000, and preferably the molecular weight is above 1,000,000 and may be above 5,000,000, for instance in the range of from 10 to 30 million or higher. The cationic polymer is substantially linear; it may be wholly linear or it can be slightly cross linked provided its structure is still substantially linear in comparison with the globular structure of cationic starch. Preferably the cationic polymer has a relatively high charge density of for instance about 0.2 and preferably at least about 0.35, and most preferably about 0.4 to 2.5 or higher, equivalents of cationic nitrogen per kilogram of polymer. When the polymer is formed by polymerization of cationic, ethylenically unsaturated monomer, optionally with other monomers, the amount of cationic monomer will normally be above 2 mole percent and usually above 5 mole percent, and preferably above 10 mole percent, based on the total moles of monomer used in forming the polymer. The amount of the cationic polymer employed in the process, in the absence of any substantial amount of cationic binder, is typically at least 0.3 percent based on dry weight of the slurry, and preferably 0.6 percent in the substantial absence of cationic binder and 0.5 percent in the presence of cationic binder, same basis, which is from 1.1 to 10 times, and usually 3 to 6 times, the amount of cationic polymer that would be used in conventional (dual polymer) processes, and hence is considered "an excess amount" of cationic polymer. The cationic polymer is preferably added to thin stock, preferably cellulosic slurry having a consistency of 2 percent or less, and at most 3 percent. The cationic polymer may be added to prediluted slurry, or may be added to a slurry together with the dilution water.
In the pulp and papermaking industry, the fraction of paper products which do not meet minimum commercial specifications and therefore cannot be sold is called broke. The broke, which usually comprises the waste or trimming from the formed web, is a valuable source of fibers, and is returned for reuse in a papermaking operation at the same or other mill. The broke derived from paper which contains coating is referred as "Coated Broke". Coating is applied to paper to improve surface smoothness which positively influences printability, and, in some cases, to provide a uniform, bright, opaque layer to cover `unattractive` base stock. Mills which make use of a relative high proportion of coated broke in the furnish are confronted with several problems due to the presence of the coating in their recycled furnish.
The coated materials contained on coated broke may account for ten (10) to about forty (40) weight percent of the total solids in the paper furnish. Typically, 80 to 90% of the dry formulation weight of coating is composed of pigments, and 5 to 20% of binders. Coating formulations often contain a large variety of components and are customized to meet stringent requirements with respect to both the paper coating itself and the handling properties of the coating dispersion.
Pigments typically used in paper coating include various types of clays, various types of calcium carbonates, and titanium dioxide. Other types of white pigments include satin white, barium sulfate, zinc oxide, talc, plastic pigments, alumina trihydrate, and titanium dioxide extenders. Organic or inorganic colored pigments are also used in some cases.
Coating binders fall into three classifications: starches, proteins and synthetics. Protein binders are either casein, soy extract, or animal glues. Synthetic binders are mainly latexes based on vinyl alcohol, styrene butadiene, vinyl acetate and acrylic polymers.
Mills which make use of coated broke in their furnish experience problems of sticky deposits originating from binder materials in combination with pigments and fillers. These deposits, often referred as "white pitch", can be found throughout the wet end, the press section, and the dryer section of a paper mill. They may cause operational problems such as holes or specks in the paper, felt filling, paper machine and coater breaks, and buildup of deposits on vacuum boxes, drying cylinders and calendar rolls. The consequence is frequent machine downtime and loss of runnability, and occasionally also loss of efficiency of chemical additives such as retention aids.
In the past, cationic solution polymers derived from crosslinked or linear epichlorohydrin dimethylamine (EPI-DMA), diallyldimethyl ammonium chloride (DADMAC), and ethylene dichloride ammonia (EDC/NH 3 ) reactants have been used to treat coated broke (J. E. Pearson; M. R. St. John "Proper Selection of Polymeric Coagulant for Coated Broke Treatment and Consequences of Selection on Overall Wet End Chemistry", Tappi Papermakers Conference 1995, p. 523). The goal of treating the coated broke with these polymers, referred to as "coagulants", is to anchor white pitch onto paper fibers while the pitch particles are still small and have not yet had the chance to combine into deposit-forming agglomerates. Coagulants also act to neutralize the effects of dispersing agents from the coating, which are detrimental to retention. In addition, coagulants help retain the fine coating pigments, resulting in improved ash retention. Treatment of coated broke by coagulants is presumed to be based on a charge neutralization mechanism and is often described as broke cationization. However, it has been shown that other mechanisms of aggregation, such as charge patch mechanism and bridging, may play a role in determining polymer activity.
In addition to the use of coagulants, Pearson has claimed in U.S. Pat. No. 5,466,338, the disclosure of which is incorporated herein by reference, that high molecular weight dispersion polymers with charge density much lower than that of coagulants can be successfully used to treat coated broke by coagulating white pitch. These dispersion polymers offer the advantage of requiring much less elaborate feeding equipment and will mix more effectively into the pulp system in comparison with high molecular weight emulsion polymers.
SUMMARY OF THE INVENTION
An improved papermaking process comprising forming an aqueous coated broke papermaking slurry and adding a blend of a water-soluble dispersion polymer and a coagulant to the slurry to increase retention and/or drainage is disclosed. The water-soluble polymer is formed by polymerizing a water-soluble mixture which comprises: (a) a first cationic monomer represented by the following formula (I): ##STR1## wherein R 1 is H or CH 3 each of R 2 and R 3 is an alkyl group having 1 to 3 carbon atoms: A is an oxygen atom or NH: B is an alkylene group of 2 to 4 carbon atoms or a hydroxypropylene group: and X - is an anionic counterion, and/or a second cationic monomer represented by the following general formula (II): ##STR2##
wherein R 4 is H or CH 3 : each of R 5 and R 6 is an alkyl group having 1 to 2 carbon atoms: R 7 is H or an alkyl group of 1 to 2 carbon atoms: A' is an oxygen atom or NH: B' is an alkylene group of 2 to 4 carbon atoms or a hydroxypropylene group: and X - is an anionic counterion: and (b) (meth)acrylamide in an aqueous solution of a polyvalent anion salt, wherein the polymerization is carried out in the presence of either an organic high-molecular multivalent cation comprising a water-soluble polymer containing at least one monomer of formula (II) or an alkyl ester of acrylic acid. After addition of the blend, the slurry is drained to form a sheet, and the sheet is dried.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph comparing turbidity reduction data for a solution polymer referred to as "coagulant", dispersion polymers, and blends of the two polymers as described in the present invention.
FIG. 2 is a graph comparing turbidity reduction data for a solution polymer referred to as "coagulant", dispersion polymers, and blends of the two polymers as described in the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
It has now been discovered that products obtained by blending a high molecular weight dispersion polymer and a high charge coagulant show improved activity in improving retention in the manufacture of paper in comparison with the single components by themselves. Both high molecular weight and charge are polymer characteristics which have been previously found to be important for coagulating white pitch. Surprisingly, a synergistic effect is obtained by blending the two components, and the ability of these products to coagulate fines components including fiber fines coating pigments (fillers) and white pitch in a papermaking slurry is higher than that obtained with the two components added at the same time but separately to the papermaking furnish.
These blends, similarly to their components, do not require the elaborate feeding equipment utilized by emulsion polymers. The blended composition may also be applied to the treatment of wastepaper furnish containing adhesives and deinked fiber.
The blend is composed of a dispersion polymer product and a coagulant in ratios 5/95 to 95/5. The dispersion polymer product contains 15-40 weight % of dispersion polymer on an active basis. The most preferred blends contain 25 to 75 weight % of dispersion polymer product, although the weight % of dispersion polymer contained in the blend which is efficient to treat the coated broke slurry depends on the nature of the slurry itself.
The blend is added to the slurry in an amount of from about 0.1 kg product per ton of total broke solids to about 5 kg product per ton of total broke solids. Most preferably, the effective treatment ranges are between 0.25 kg product per ton of total slurry solids to about 3 kg per ton, although the treatment level demand for the blends can vary with the type of slurry being treated.
Preferably, the dispersion polymer and coagulant are blended as concentrated products prior to diluting to use levels and adding to the slurry. Alternatively the dispersion polymer and coagulant may be diluted separately and then added to the slurry.
The coagulants of the invention are preferably selected from the group consisting of epichlorohydrin dimethylamine, diallyldimethyl ammonium chloride, polyaluminum chloride, alum, polyethylenimine, dicyandiamide, ethylene dichloride aumnonia and mixtures thereof.
The following examples are presented to describe the preferred embodiments and utilities of the invention and are not meant to limit the invention unless otherwise stated in the claims appended hereto.
EXAMPLES
Coated broke slurry was prepared in the laboratory from dry broke pulped in Synthetic Chicago Tap Water #13 for 1 hour and 45 minutes by using a high consistency pulper, and successively disintegrated in a standard disintegrator for 10000 to 45000 revolutions according to the type of broke.
Reduced specific viscosity/intrinsic viscosity (RSV/IV) measurements were carried out by capillary viscosimetry under standard conditions (0.125M NaNO 3 , 30° C.,). RSV is the polymer reduced specific viscosity at 0.045% polymer weight. IV of the polymer is the intercept of the best line calculated from RSV points at three different polymer weight concentrations. Viscosity of the blends was calculated on the basis of percent weight of dispersion polymer present in the blend. Such a calculation allows measurement of viscosity changes that the dispersion polymer undergoes upon its blending with the coagulant.
Polymers were diluted to 0.2-0.4% product for activity testing. Polymer activity was tested in wet coated broke slurry collected at the paper mill or in coated broke slurry prepared in the laboratory from dry broke as outlined above. A simple turbidity test used to evaluate polymer activity. To 200 ml of broke in a 400-ml beaker, stirred at 500 rpm by using a Britt Jar mixer, blends of a dispersion polymer and solution polymer or individual components were added at 10 seconds. In any case, stirring was stopped at 30 seconds, and the mixture was filtered through a 100-mesh sieve to the same volume of filtrate each time. By this method, retention of coated broke particles is a result of polymer activity and not filtration by the filter medium. The filtrate turbidity was measured by a standard turbidity meter (2100 N Turbidimeter by Hach Company) calibrated by using Formazin Primary Standard as suggested by the manufacturer. Retention was expressed in terms of % turbidity reduction of the filtrate from broke with no polymer treatment (blank).
EXAMPLE 1
Polymer A: EPI-DMA solution polymer
Polymer B: 90/10 AcAm/DMAEA·BCQ
Polymer C: 50/50 blend polymer A/polymer B
Polymer D: 25/75 blend polymer A/polymer B
Polymer E: 75/25 blend polymer A/polymer B
TABLE I______________________________________Polymer % Actives RSV dl/g! IV dl/g!______________________________________A 45.3B 15.0 15.1 12.1C 30.2.sup.a 16.2 13.2D 22.6.sup.a 14.0 11.3B 37.7.sup.a 18.8 15.4______________________________________ .sup.a % actives of blends C, D, E, were calculated from the % actives of their two components, polymer A and polymer B.
Dosage curves based on turbidity reduction for polymers A, B, C, D, and E are presented in FIG. 1. The polymers in the example were calculated as product weight, and their dosage is based on dry weight of coated broke. FIG. 1 clearly demonstrates that polymer C, polymer D and polymer E, which are blends of polymer A and B in various ratios, exhibit the highest % turbidity reduction per product dose. In particular, polymers C, D and E have a higher efficiency (retention obtained at a fixed polymer dosage) than polymers A and B individually. The activity of the blends depends on the weight % ratio of their product components, the optimal one depending on the nature of the coated broke treated. Furthermore, it was found that the retention activity of polymers A and B added separately to the broke is lower than that of polymers C, D and E, in which the two products are premixed. In particular, addition of 1 kg/ton of polymer C produces a turbidity reduction of 76.6%, whereas polymer A and polymer B added at the same time, but separately, to the broke at a dosage of 0.5 kg/ton each, give a turbidity reduction of only 53.5%. Addition of polymer E at a dosage of2 kg/ton produces a turbidity reduction of 92.8%, whereas individual addition of polymer A (1.5 kilogram/ton) and polymer B (0.5 kilogram/ton) to the broke reduces the turbidity of only 88.8%.
As can be seen from the viscosity data reported in Table I, the viscosity of polymer B varies when this polymer is present in blends with polymer A. Therefore, the viscosity data suggest the existence of specific interactions between premixed polymer A and dispersion polymer B. These interactions may explain the enhancement of retention activity observed for the blend in comparison with the retention activities produced by the two components added at the same time but separately to the broke.
EXAMPLE 2
TABLE II______________________________________Polymer A: EPI-DMA solution polymerPolymer F: 65/25/10 AcAm/DMAEA.BCQ/DMAEA.MCQPolymer G: 75/25 blend polymer A/polymer FPolymer % Actives RSV dl/g! IV dl/g!______________________________________A 45.3F 20.0 16.3 13.8G 39.0.sup.a 19.4 15.7______________________________________ .sup.a % active of blend G was calculated from the % actives of their two components, polymer A and polymer B.
Polymers A, F and G were tested on fresh wet broke used at the mill immediately after its collection. As shown in FIG. 2, polymer G, which is a blend of the coagulant A and dispersion polymer F, has efficiency and effectiveness considerably higher than those of the single components of the blend, polymers A and F. The polymers in the example are calculated as product weight, and their dosage is based on dry weight of coated broke.
Also in this case, the viscosities of the dispersion polymer which has been blended with polymer A is different from that of the dispersion polymer alone. (Table II) This change in viscosity indicates the presence of specific interactions between the coagulant and the dispersion polymer. These interactions may explain the retention activity benefits obtained by using the blends over the single products alone.
EXAMPLE 3
The activity of four polymers was tested in a wet coated broke slurry. Polymer A was an EPI-DMA solution polymer; polymer B was a 90/10 AcAm/DMAEA·BCQ dispersion polymer; polymer H was a 50/50 blend of polymer A and B, Polymer H and J had the same composition but differ in the method of preparation. Polymer H was prepared by mixing polymer A and B as concentrated products. This mixture was diluted to a working concentration of 0.285 wt % before testing. Polymer J was prepared by mixing diluted solutions of polymer A and polymer B at 0.285 wt %. Polymers H and J had the same activity. Both products outperformed their single components. Additionally, these blends outperformed their single components added at the same time but separately to the broke. These results suggest that the dispersion polymer-coagulant interactions invoked to explain activity enhancement of the blends, are favored regardless of the concentration of the dispersion polymer and coagulant.
Changes can be made in the composition, operation and arrangement of the method of the present invention described herein without departing from the concept and scope of the invention as defined in the following claims: | An improved papermaking process comprising forming an aqueous coated broke papermaking slurry and adding a blend of a water-soluble dispersion polymer and a coagulant to the slurry to increase retention and/or drainage is disclosed. After addition of the polymers, the slurry is drained to form a sheet, and the sheet is dried. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS:
None. However, a Disclosure Document No. 032273 was filed on May 20, 1974.
BACKGROUND OF THE INVENTION:
1. Field of the Invention
This invention relates to agricultural irrigation and more particularly to moving an agricultural irrigation system and maintaining it in alignment as it is moved.
2. Description of the Prior Art
Irrigation systems which move in a circle around a pivot are well known and commercially available on the market. Also, there are many arrangements for driving the systems and maintaining them in alignment as they are driven. There has been previously patented a system where a taut line was stretched from one end of the system to the other and the individual vehicles prevented from moving by dropping a block into a mechanical movement system, Boone U.S. Pat. No. 3,302,656.
Previous systems have been operated by hydraulics and in such systems, traditionally, a single line extends to each vehicle and two valves are required on each vehicle. One of these valves throttles the fluid into the power cylinder for alignment purposes and the other valve switches the fluid under pressure to one side or the other of the piston.
SUMMARY OF THE INVENTION
1. New and Different Function
We have provided a system which is extremely simple and, therefore, trouble-free. It is driven by hydraulics, but no valves whatsoever are located on the vehicles themselves; only one main valve is used on the entire system. The simplicity of the system results in an extremely inexpensive system as well as one which is trouble-free.
In our system, hydraulic fluid is pumped into one side of the piston located on each vehicle until the piston moves for its full permitted stroke. When all of the pistons have moved their full permitted stroke, the hydraulic pressure increases inasmuch as there is no further place for it to go. After this increase in hydraulic pressure, the pressure in two tubes is reversed. The pressure is pumped to the other side which reverses all of the pistons. If a vehicle is forward of its proper position in line, the piston is blocked from movement and, therefore, the piston moves only slightly or not at all.
2. Objects of the Invention
An object of this invention is to move agricultural irrigation pipe and maintain it in alignment as moved.
Further objects are to achieve the above with a device that is sturdy, compact, durable, lightweight, simple, safe, efficient, versatile, and reliable, yet inexpensive and easy to manufacture, install, adjust, operate, and maintain.
Other objects are to achieve the above with a method that is versatile, rapid, efficient, and inexpensive, and does not require skilled people to install, adjust, operate, and maintain.
The specific nature of the invention, as well as other objects, uses, and advantages thereof, will clearly appear from the following description and from the accompanying drawing, the different views of which are not necessarily to the same scale.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic representation of the system according to this invention.
FIG. 2 is an enlarged schematic representation of one embodiment of this system.
FIG. 3 is a side elevational view of one vehicle according to an embodiment of this invention taken substantially on line 3--3 of FIG. 2.
FIG. 4 is a schematic representation showing one embodiment of the method of sequencing the pressure on the hydraulic tubes.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawing and more particularly to FIGS. 1 and 2, there may be seen an irrigation system. This irrigation system has central pivot 10 about which main irrigation pipe 12 is attached. A well or other source of water under pressure 14 provides water by conduit 16 to the pivot 10. Sprinklers 18 on the pipe provide means for sprinkling the water upon land. The pipe is supported by a plurality of vehicles 20. As described to this point, the system is conventional and commercially available upon the market.
Referring to FIG. 3, each vehicle has a frame including main beam 22 and two struts 24, the struts extending from the ends of the main beam 22 to support the pipe 12. These are generally in a triangular shape as shown. Two wheels 26 are at either end of the main beam 22. The wheels are driven by dogs 28 upon drive rods 30. The drive rod is driven by fluid power or hydraulic cylinder 32. Piston rod 34 of the cylinder 32 is connected to head 36. The two driving rods 30 are connected to the head 36 and the head is supported by oscillating element 38. The lower portion of the element 38 is pivoted to an ear depending from the main beam 22. It will readily be understood that as hydraulic pressure is connected to either end of the hydraulic cylinder 32, the vehicle will be driven forward in the direction of arrow T. Although the additional material to this point may not be typical or conventional, such hydraulic mechanical drives for irrigation systems are not novel.
Alignment wire 40 is stretched from one end of the system to the other. Arm 42 is pivoted at about its center to one of the struts 24 on each vehicle 20. The alignment wire 40 is attached to the upper extremity of the arm 42. The lower extremity of the arm 42 is attached to block connector 44. Block arm 46 is pivoted at its middle to support 48 which extends from strut 24 to main beam 22. Block 50 is attached to one end of the block arm 46 and counterweight 52 is attached upon the other.
As seen in the drawing and particularly FIG. 3, if the vehicle is in line or behind the other vehicles as determined by the relative position of the vehicle 20 to the alignment cable 40, the block connector 44 will be at an acute angle to the block arm 46 and will hold the block 50 above block head 54 on top of the head 36. However, it may be seen that if the vehicle 20 moves forward, which is to say in the direction of travel T, with respect to the alignment as indicated by the position of the alignment wire 40, the block connector 44 will move to a position approaching right angles to the block arm 46 which will push the block 50 down. It will be seen that as the block 50 is pushed down, it will engage the block head 54. Also, it will engage behind the catch upon the block head 54 and, therefore, block the block head 54 and the head 36 to which it is attached in the forward position, which is to say it will block the head with the piston rod 34 fully extended. Therefore, if reasonable hydraulic pressure is applied to the cylinder 32, the head will not move. The pressure applied to the hydraulic cylinder is normally enough to move the wheels forward, but not enough to bend the middle of the frame, and the vehicle will not be moved as long as the block 50 is in place.
It may be seen that no close machine tolerences or the like need be applied to the blocking system. I.e., if the head has an inch or two play or movement when the block 50 is in place, this actually has an advantageous effect. I.e., a slight movement, such as one inch, is not enough for another lug on the wheel 26 to be engaged by the dog 28 and, therefore, there is no forward movement. On the other hand when the other vehicles have moved forward so the alignment wire 40 is again in a position to lift the block 50, as hydraulic pressure is applied to the cylinder 32, there will be no force or pressure upon the block 50 and, therefore, it will lift easily from the block or locking position to the raised position as is illustrated in FIG. 3. Other means for detecting misalignment than that illustrated could be used as well as other means for blocking the movement of the cylinder responsive to that detection.
Referring to FIG. 2, it may be seen that the end vehicle has no blocking system, thus, the end vehicle continuously operates causing the end vehicle to move with the ever reversal of pressure upon tubes 56 and 58. The basic system as shown in FIG. 2 is quite simple. I.e., pump 60 pumps hydraulic fluid from reservoir 62 into the outlet pipe 64. The outlet pipe is connected to reversing valve 66. In the present position of the reversing valve, the outlet pipe is connected to what has been designated as the power tube 58. When connected to the power tube 58, fluid is directed to each of the cylinders 32 to move the dogs 28 against the lugs in the power stroke, which is to say, move each of the vehicles 20 forward in the direction of travel T. As shown schematically in FIG. 2, any of the individual pistons in the cylinders 32 may be fully retracted or fully extended, but as additional hydraulic fluid is pumped by the pump 60 into the power tubing 58, they will continue to extend until all of the pistons are fully extended. A pressure relief valve in outlet pipe 64 (not shown in FIG. 2) is set within the design limitations of the pump 60 and limits the maximum pressure applied upon the tubing 56 and 58.
At some time after all of the pistons are fully extended, reversing valve 66 is reversed so the output of the pump 60 is directed to the retract tube 56 and the tube 58 is bled back to the reservoir 62. At this point, it may be seen that all of the cylinders 32 will thereafter retract, which is to say, move so the rod 34 is fully retracted. Obviously, if the block 50 is lowered in the block head 54 in any of the vehicles, that cylinder will become fully "retracted" without appreciable movement. After all of the cylinders 32 are retracted, the reversing valve 66 is again reversed.
It will be understood that reversing valve 66 could be reversed by a simple timing mechanism. I.e., every 60 seconds it could be reversed, having previously been determined that 50 seconds is sufficient time for hydraulic fluid to completely fill all the cylinders 32. Of course, if some of the vehicle cylinders are blocked, the excess fluid is bypassed by a pressure relief valve (not shown in FIG. 2) to the reservoir 62.
We prefer to use a system wherein the reversing valve 66 is reversed responsive to an increase in pressure in the output 64 of the pump 60. One embodiment of such a system is shown in FIG. 4.
Referring to FIG. 4, it may be seen that flow limiting valve 68 is attached in the outlet 64 of the pump 60 to regulate the speed at which the irrigation system is moved. Pressure limiting valve 70 is attached to the outlet 64 to relieve the excess fluid to the reservoir. As stated before, the outlet pipe 64 is connected to reversing valve 66, which is shown in a position where the fluid from the pump 60 is directed into the power tube 58. The retract tube 56 is shown being directed by the reversing valve 66 back to the reservoir. The outlet pipe 64 is also connected to pilot valve 72 which controls the main reversing valves 66. The pilot valve 72 is controlled by retract pressure control valve 76 connected to retract tube 56 and power pressure control valve 78 connected to power tube 58. Bleed check valve 74 bypasses the retract pressure control valve 76 and bleed check valve 80 bypasses power pressure control valve 78.
Analyzing the operation from the position of the valves as seen in FIG. 4, it may be seen that as the pump 60 continues to operate it will continue to pump fluid through power tube 58 until all of the cylinders 32 become cockablock. At this time the fluid can no longer flow into the cylinders 32 causing the pistons to move and, therefore, the pressure will increase. When the pressure increases, it will cause an increase of pressure on the control valve 78 which will cause it to move to place pressure on power inlet 88 of the pilot valve 72. This pressure increase will cause the pilot valve to reverse. The pilot valve is permitted to reverse by the fluid flowing from the retract inlet 86 through the bleed check valve 74 into the retract tube 56 which in this condition is at low pressure. When the pilot valve 72 reverses, this reverses the pressure upon reversing valve 66 and then reversing valve 66 will reverse. It will be noted that by using the pilot valve 72, there are no dead center positions. I.e., pressure is continually applied through power inlet 88 until the pilot valve 72 has changed positions; then, when it changes position, pressure is then applied to reverseing valve 66. When valve 66 is reversed, pressure will then be applied to retract tube 56 until all of the cylinders 32 are again cockablock in the retracted position at which time the pressure increase on retract tube 56 will cause the retract pressure control valve 76 to apply pressure to the retract inlet 86 at which time the valves are again reversed.
Thus it may be seen, that with the simple reversing valve system as seen in FIG. 4 for an entire system, no valves whatsoever are applied to the cylinders 32 on the vehicles 20. Also, as noted before, although FIG. 4 shows the preferred reversing valve system, other types of pressure reversing systems may be used.
We have found with this particular type system that it is possible to use a mixture of fluids in the lines. The system is basically a "surge" system. The fluid at the end of the tubes 56 and 58 near the end vehicle is never pumped through the pump nor is ever used in the reversing valve systems. Also, there is little fluid flow near the end of the system. Therefore, it is possible to charge the lines with an inexpensive fluid, such as diesel oil or kerosene, in both the retract tube 56 and the power tube 58 and to charge the system with more expensive hydraulic fluids at the pump where it is surged from one line to the other.
By the term "cockablock" is meant that all of the elements have moved as far as possible and the elements, therefore, are capable of moving no further because they are blocked.
It will be understood by those skilled in the art that the individual cylinders 32 could be retracted by means other than the hydraulic fluid in manifold 56. A ready example of the other retracting means would be a spring attached to each cylinder 32 or water pressure from pipe 12 could be used to retract each cylinder 32. A hydraulic pressure much greater than the water pressure would be used to power the cylinders 32 in manifold 58, readily overcoming the water pressure.
The embodiment shown and described above is only exemplary. We do not claim to have invented all the parts, elements or steps described. Various modifications can be made in the construction, material, arrangement, and operation, and still be within the scope of our invention. The limits of the invention and the bounds of the patent protection are measured by and defined in the following claims. The restrictive description and drawing of the specific example above do not point out what an infringement of this patent would be, but are to enable the reader to make and use the invention. | A pivot or circle type irrigation system has a single hydraulic cylinder upon each vehicle to provide motive force to that vehicle. Two hydraulic tubes extend the length of the system and each hydraulic tube is connected to one side of each cylinder without valves. The cylinder movement is blocked if the vehicle upon which it is mounted is detected to be ahead by an alignment system. Hydraulic fluid is pumped into one tube until an increase of pressure indicates that all of the cylinders are cockablock and then the tubes are reversed and hydraulic fluid is pumped into the other line until, again, a rise in pressure indicates that all of the cylinders are cockablock. | 0 |
This application claims the benefit of and is a continuation of U.S. application Ser. No. 11/375,931, filed on Mar. 15, 2006, which is a non-provisional of U.S. Provisional Application Ser. No. 60/662,807 filed on Mar. 15, 2005, which are both hereby expressly incorporated by reference in its entirety for all purposes.
BACKGROUND
This disclosure relates in general to audio and video licensing and, but not by way of limitation, to moving of licensed audio and video to new computing devices.
Today there are software players that play audio and video downloaded from the Internet or obtained through other sources. The availability of digital rights management (DRM) has made copyright holders more comfortable with this new paradigm of licensing their audio and video in downloadable form. Different software players use different and incompatible DRM that slows adoption by consumers.
A consumer who downloads a song from one download service has to play the song on the corresponding proprietary player. A DRM used by the corresponding proprietary player ties a consumer to that player. Another player is unlikely to play the song as the DRM prevents this use inadvertently because it is incompatible with the DRM used by the new player. For example, a consumer may download a song from the Apple™ music store for their iTunes™ player. Later, should the consumer decide to start using the Rhapsody™ Jukebox, the song would not play. The consumer may have to purchase the song again even though there are arguably rights to use the song with any player.
There are programs that disable or strip the DRM from a song such that it can be used with most player. Some take the position that this type of software is illegal and violates the Digital Millennium Copyright Act (DMCA) in the United States or some other law. Additionally, there are programs that will transcode one codec into another. These programs take a song that might be in a proprietary format and convert it to a format that can be used in a new player. Between the DRM stripping software and the transcoding software, consumers can move their music collection to a new player. This process is complex and, some might say, illegal.
SUMMARY
In one embodiment, the present disclosure provides a content distribution system for transporting audio or video licenses between content players that use digital rights management (DRM). The content distribution system includes at least a second license repository and an authentication engine. The second license repository receives second information describing a second plurality of content licenses. A first license repository stores a first plurality of content licenses. The first plurality of content licenses enable use of a plurality of content objects with a first content player within confines of DRM. The second license repository is geographically distant from the first license repository. The authentication engine authorizes the second plurality of content licenses of the second license repository. The second plurality of content licenses enable use of the plurality of content objects with the second content player within the confines of DRM.
In another embodiment, the present disclosure provides a method for transporting content licenses from a first content player to a second content player. In one step, a plurality of content licenses is read from a first repository of the first content player. The plurality of content licenses enable use of a plurality of content objects within confines of DRM. The plurality of content licenses are associated with a plurality of licensors. The plurality of content licenses is sent to a store, which is geographically remote to the first repository. Authentication information of a licensee of the plurality content licenses is sent. The plurality of content licenses is written to a second repository of the second content player. The second content player can use the plurality of content objects within the confines of DRM.
In yet another embodiment, the present disclosure provides a method for transporting audio or video licenses between content players. In one step, first information is received that describes a first plurality of content licenses at a point. A first repository stores the first plurality of content licenses. The first plurality of content licenses enable use of a plurality of content objects on a first content player as allowed by DRM. The point is geographically remote to the first repository. A licensee of the first plurality content licenses is authenticated. Second information is sent that enables a second plurality of content licenses corresponding to the first plurality of content licenses away from the point. The second plurality of content licenses is stored with a second repository of the second content player. The second plurality of content licenses allows use of the plurality of content objects on the second content player as allowed by DRM.
Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating various embodiments, are intended for purposes of illustration only and are not intended to necessarily limit the scope of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
The present disclosure is described in conjunction with the appended figures:
FIGS. 1A through 1G depict block diagrams of embodiments of a content distribution system; and
FIGS. 2A , 2 B and 2 C illustrate flowcharts of embodiments of a process for migrating licensed content to a new content player.
In the appended figures, similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.
DETAILED DESCRIPTION
The ensuing description provides preferred exemplary embodiment(s) only, and is not intended to limit the scope, applicability or configuration of the disclosure. Rather, the ensuing description of the preferred exemplary embodiment(s) will provide those skilled in the art with an enabling description for implementing a preferred exemplary embodiment. It being understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope as set forth in the appended claims.
There are many content download services available. Users download content (e.g., songs, software, videos, sound, books) to a computing device (e.g., personal computer, mobile phone, music player, personal video recorder, set top box, portable video player) for their enjoyment. To control access to these files, various forms of digital rights management (DRM) are used. The player hardware, software-based players, storage devices, and delivery channels may all have DRM to control access and enforce copyright licenses. For example, Microsoft™ Windows has DRM that controls access to music and video files.
Different applications and hardware control DRM in different manners, but generally store a list of copyright licenses for a particular file or stream. An identifier code is either embedded in the content object or associated with the content object in some way. The DRM application program interface (API) is provided with the content object itself or the identifier code in determining if a copyright license is available. Generally, where there is no copyright license, the DRM prevents or restricts use of the content object. Even though the content file is available, the DRM prevents playback.
Referring initially to FIG. 1A , an embodiment of a content distribution system 100 - 1 is shown. This embodiment shows two content providers 108 and two users 112 , but it is to be understood that there may be any number of content providers 108 and users 112 in various embodiments. The user 112 could be the same person working with two computing devices 124 in an upgrade process. For example, the user may have music or video on the first computing device 124 - 1 and wish to move the music or video to the second computing device 124 - 2 for use. A migration system 178 can have various configurations to aid the move to the second computing device 124 - 2 .
This embodiment shows two content originators 102 , but there could be any number content originators. Content originators 102 may be content subscription and/or download services that have content they own or have the right to license stored in a remote content store 156 . A content provider 108 gives access to the content objects through a content web site or application interface 116 . Licenses granted to the content objects are stored in the remote license database 140 . The remote license database 140 can be used to provide content licenses to the new computing device 124 in a migration situation. A migration system may pass the content licenses to the new content player 128 , but could verify their validity at the various remote license databases 140 for the content objects of the user 112 .
In this embodiment, the computing device 124 includes a content player 128 , a local content store 160 , a local license database 136 , and optionally, a content transcoder 164 . In various embodiments, the local content store 160 and local license database 136 could be coupled to the content player 128 using an integral and/or internal storage medium, an external storage medium and/or a networked storage medium. A user 112 interacts with the computing devices 124 to play or realize the content objects resident in a local content store 160 and/or streamed from a remote content object store 156 .
Users 112 often upgrade their software and/or hardware for various reasons. During this process, copyright licenses can be lost due to compatibility and integration problems in conventional systems. FIG. 1A is simplified in that it shows only one local license database 136 for each computing device 124 , but often each DRM technique and/or player maintains its own local license database 136 such that the computing device 124 may have many local license databases 136 .
Local license databases 160 in computing devices 124 are often not compatible with each other, even though the content object could be used with different content players. For example, Apple™ iTunes™ uses a DRM incompatible with that used by Microsoft™ Windows Media Player™ such that content licenses cannot be exchanged between the two even though the players could play each-others content with the proper codec support.
This embodiment uses a content transcoder 164 and at least one remotely-located license databases 152 , 140 to migrate the content objects and content licenses to a new computing device 124 . A secured content object (i.e., a content file or stream protected by DRM) may be used on another computing device 124 , but the copyright license would not follow the user 112 to the other computing device 124 in conventional systems. For example, a first music player may recognize a content file and allow playing because the DRM recognizes a copyright license, but a second music player may recognize the content file without being able to recognize a copyright license such that access is prevented.
One embodiment of the invention allows transport of a local license database 136 between various computing devices 124 that a user 112 might use. A software application, software applet or the content player itself can pass all or some of the local license database 136 to a global license database 152 or a remote license database 140 . Passing of the local license database 136 is done opaquely in some embodiments using encryption to protect the information. The copyright licenses on the old computing device 124 are no longer usable once passed to the global license database 152 or a remote license database 140 . The user can authenticate their right to copyright licenses with the new computing device 124 and have the new local license database 136 populated by opaquely passing the copyright licenses to the local license database 136 of the new computing device 124 .
The migration system 178 may have to communicate with the various content originators 102 associated with each content object. Further, the content licenses may be translated to a format for the DRM of the new computing device 124 . In some cases, the contents of the local license database 136 are not transferred, but an abbreviated listing of the licenses could be transferred. The content originator 102 may track the content licenses of each user and the migration system 178 could update the content originators 102 as the migration takes place.
The content player 128 or another application passes the licenses in opaque form to the global license database 152 , which acts as an intermediary between the old local license database 136 - 1 and a new local license database 136 - 2 . The licenses may or may not be opaque to the global license database 152 . Where the license information is kept opaque, only the content player 128 - 2 of the new computing device 124 - 2 understands how to decode and reactivate the licenses. Public or private keying can be used in various embodiments encrypt the content licenses during transport.
Content transported to the new computing device 124 - 2 can then be played after any re-formatting by a content transcoder 164 . In this embodiment, the content transcoder is in the new computing device 124 - 2 , but in other embodiments could be in the old computing device 124 - 1 , the content originator 102 , the migration system 178 , or elsewhere. After sending the content licenses, content objects on the old computing device 124 - 1 cannot pass the DRM checks to allow playback on the old computing device 124 - 1 . The content objects on the old computing device 124 - 1 could be deleted to further prevent unauthorized use. Some embodiments may allow paying a fee to allow both the old and new computing devices 124 to retain licenses to play the content objects. Such an arrangement can be offered by the content originators 102 .
Where the global license database 152 is not opaque to the licenses, the global license database 152 can serve as a clearinghouse for the various computing devices 124 . An application on the computing device 124 could opaquely send the local license database to the global license database 152 where the licenses are converted to plaintext. A different content player 128 using a different license format could request the content licenses from the global license database 152 after proper authentication of the licensee. The content licenses would be converted to the native format of the different content player 128 and sent opaquely to the different content player 128 . In this way, content licenses could be exchanged between incompatible content players 128 . Some embodiments may confirm the licenses before movement by checking with the content originator 102 who originally granted the license to the user 112 .
In some cases, the new computing device 124 and/or content player 128 may not understand the old format of the content object. A conversion application or content transcoder 164 could transcode the content object to allow it to be compatible with the new computing device 124 and/or content player 128 . The conversion application could be located anywhere in the content distribution system 100 , for example, at the content provider 108 , the global license database 152 or the computing device 124 (as in this embodiment).
Some embodiments could download the content object from the content provider 108 in the new format after destruction of the old content object and verification that the license is valid. There may or may not be an additional charge for the download in the new format. A replacement content license could be included along with the content object in the new format.
In one embodiment, the computing device 124 - 1 does not actually transport the licenses to the new computing device 124 - 2 , but destroys the licenses in the local license database 136 - 1 and merely reports the destruction to the remote or global license database 140 , 152 . Once destroyed, a new computing device 124 - 2 can receive the content licenses in any format compatible with the computing device 124 - 2 and/or content player 128 - 2 . The contents of the local content database 136 - 1 may already be known to the remote or global license database 140 , 152 such that only destruction need be communicated and those content licenses become available for the new content player 128 - 2 .
One embodiment uses a removable storage media (e.g., magnetic disk, optical disk, flash media, hard drive, optically readable media) to transport the content licenses to the new local license database 136 . The removable storage media can be loaded with the content licenses in an opaque form. The new computing device 124 could load the content licenses and destroy the ability to load the content licenses on another computing device 124 . For example, the content licenses could be erased. Another embodiment could require authentication from a remote trusted party before reading the content licenses into the new local license database 136 - 2 . The remote trusted party would only allow reading the content licenses on one or a set number of computing devices 124 as allowed by the license. The content objects could also be transported with the removable storage media.
Authentication of the licensee before loading the content licenses on the new computing device 124 can be explicit or implicit. Where the license is to a person or group of persons, a password or biometric authentication technique can be used. For implicit authentication, the content licenses are not tied to a particular user but tied to possession of a code or the removable storage media. For example, whoever enters a pass code or possesses the removable storage media with the content licenses can load them onto the new computing device 124 . An authenticating party can enforce the number of simultaneous users of the content licenses, such that if another tries to use the content licenses beyond their terms, access could be denied. For example, if someone steals the removable storage media, that person could use the content licenses unless they have already been loaded on the specified number of computing devices 124 already.
With reference to FIG. 1B , this embodiment of the content distribution system 100 - 2 does not use a global license database 152 . To enable the content objects on the new computing device 124 , the copyright licenses are opaquely sent back to the content originator's 102 remote license database(s) 140 . Alternatively, the licenses could be looked-up at the content originators 102 without actually sending the content licenses back. In some cases, the user 112 could have downloaded content objects from a number of content providers 108 such that a number of corresponding remote license databases 140 would be used in migrating to the new computing device 124 .
The copyright licenses can be opaquely downloaded to the new computing device 124 from the remote license database(s) 140 after proper authentication of the user 112 . Additionally, the content objects could reformatted for the new content player using a content transcoder 164 . Instead of transcoding, the content originator 102 may have the content objects previously encoded to the new format that are ready for loading on the new computing device 124 . The new computing device 124 - 2 also has a content transcoder 164 - 2 available for transcoding the content files for the new format.
This embodiment includes an authentication engine 172 at the old computing device 124 . The authentication engine 172 could be integral to the content player 128 or operating system. Once the user 112 authenticates their identity, the license transfer is authorized. The content objects could be transferred over the Internet 120 or some other connection. In this embodiment, the old computing device 124 - 1 is a personal computer and the new computing device 124 - 2 is a handheld phone. The user 112 may connect the handheld phone to the personal computer with Bluetooth™ or a USB cable to transfer content objects and content licenses.
Referring next to FIG. 1C , a block diagram of another embodiment of a content distribution system 100 - 3 is shown. This embodiment includes a migration system 178 that has a global license database 152 , a content transcoder 164 , an authentication engine 172 , and a global content store 168 . The global license database 152 can be used to hold the content licenses when transferring them. Similarly, the content objects can be stored in the global content store 168 before loading onto the new computing device 124 - 2 . Any reformatting of the content objects is performed on the content transcoder 164 . Authentication of the user and the content licenses can be performed by the authentication engine 172 .
With reference to FIG. 1D , a block diagram of yet another embodiment of a content distribution system 100 - 4 is shown. In this embodiment, the content licenses can be stored in the global license database 152 in a manner that is accessible to any computing device 124 . If the user 112 authenticates their identity to the satisfaction of the computing device 124 and/or global license database 152 , the content player 128 will allow playback of a content object on the computing device 124 . The content licenses are not stored local to the computing device 124 . The content licenses are verified as needed before playing the content object.
Another embodiment allows storage of licenses in the global license database 152 in a way that allows individual licenses or a group of licenses to be checked out to a computing device 124 . After authentication of the user 112 , the content licenses corresponding to the content requested for playback are checked out to allow use. The user 112 can manually check-in the licenses or the licenses could automatically be checked-in after a period of time unless checked out again.
In this embodiment, the content originators 102 do not track which licenses are issued to users 112 . The content originators 102 rely upon the global license database 152 . When content objects are licensed, the content licenses could be written to the global license database where they are accessible to the content providers 102 and computing devices 124 on demand.
Referring next to FIG. 1E , a block diagram of still another embodiment of a content distribution system 100 - 5 is shown. In this embodiment, the content objects are not stored at the computing devices 124 . Content objects are stored in a global content store 168 . Upon proper authentication 172 , a recipient 112 can realize content objects on any computing device 124 with any type of content player. The DRM is still provided by the computing device, but the licenses and content objects are stored at the migration system 178 and/or the content providers 102 .
The content player 128 can check out a content object and license as needed from either the migration system 178 or the content originator 102 . The licenses and content objects can be checked back in or just set to expire after a period of time. The recipient 112 may be charged for the ability to have transportability of content objects between a number of computing devices. The number of computing devices that can be used may be limited. Some embodiments may prevent simultaneous use of the same content object or may prevent use of the migration system by more than one computing device at one time.
The number of times a content object is played could be tracked and reported to gage popularity. Some embodiments could insert commercials into the sequence of content objects. Impressions for those commercials could also be reported.
With reference to FIG. 1F , a block diagram of one embodiment of a content distribution system 100 - 6 is shown. In this embodiment, the migration system 178 is used during the transition to the new computing device 124 . The content transcoding, storing of content licenses and authentication is performed by the migration system 178 . The user 112 may pay for this service. In one embodiment, the seller or manufacturer of the new computing device 124 subsidizes or pays for this cost.
Referring next to FIG. 1G , a block diagram of another embodiment of a content distribution system 100 - 7 is shown. In this embodiment, the content originator 102 can be used to authenticate the content licenses or be used to migrate the content objects to the new computing device 124 without using the migration system 178 . For example, the content originator 102 could be used where available, but the migration system 178 where the content originator 102 cannot be found or has no history of the license. This might occur for content object delivered in tangible form (e.g., on a disk or tape) where there was no electronic delivery.
With reference to FIG. 2A , a flowchart of an embodiment of a process 200 - 1 for migrating licensed content to a new content player 124 - 2 is shown. The process 200 - 1 can be largely automatic after the user initiates the process in block 204 . The user manually authenticates herself also in block 204 . Authentication may include entry of license codes and/or login information. The authentication information may be entered through either the old or new computing devices 124 . The new player is manually identified in step 208 . The content objects are transferred to the new computing device automatically in block 212 . Some embodiments move the content objects directly from one local content store 160 to another, but other embodiments use a remote or global content store 156 , 168 as a waypoint between the old and new local content stores 160 .
In block 216 , any transcoding or exchange of the content objects is performed. Some embodiments transcoder the content objects, while others get another copy of the content object that is already coded properly. Transcoding can be performed at either computing device 124 , the migration system 178 or the content originators 102 in various embodiments. Also in block 216 , the content objects are loaded on the target computing device 124 - 2 .
This embodiment allows the user to upgrade his or her licenses to the content objects as determined in block 218 . Upgrading licenses could involve a number of content originators 102 and could be managed by the migration system 178 . There could be an option to upgrade to a two computing device 124 license allowing the content objects to simultaneously exist on the two computing devices 124 . Another option could allow more computing devices 124 or even an unlimited number of computing devices 124 . Where there is an upgraded license, processing skips over blocks 220 and 224 to step 228 .
Where there is no upgrade of licenses, processing goes from block 218 to block 220 where the content licenses are uploaded to the migration system 178 opaquely to avoid interception or decoding. Encryption can be used in this process. The migration system 178 may or may not be able to decode the content licenses before they are passed along. Somewhere, the content licenses are reformatted for the new content player 128 - 2 and DRM. In block 224 , the content licenses and content objects on the old computing device 124 - 1 are disabled or destroyed.
In block 228 , the content licenses are sent and loaded onto the new computing device. The transport can once again be opaque to avoid interception. At this point in the process 200 - 1 , the content files and licenses are recoded and on the new computing device 124 - 2 such that they are available for use with full DRM support of the new content player 128 - 2 . This process may be repeated for new content players as the need arises such that a user can avoid wholesale repurchase of licenses in this embodiment.
Referring next to FIG. 2B , a flowchart of another embodiment of a process 200 - 2 for migrating licensed content to a new content player 124 - 2 is shown. This embodiment replaces blocks 218 and 220 with new block 222 . After the content objects are loaded, the content licenses or an indicator thereof is send to the migration system 178 . An indicator could simply be an account identifier for a content originator 102 . The migration system 178 could go to the content originator 102 to get all the content licenses associated with the account that is identified. This embodiment does not allow upgrading the content license and performs block 224 in every case before completing blocks 228 and 232 as in the embodiment of FIG. 2A .
With reference to FIG. 2C , a flowchart of yet another embodiment of a process 200 - 3 for migrating licensed content to a new content player 124 - 2 is shown. This embodiment differs from that of FIG. 2B in that blocks 212 and 216 are replaced by blocks 214 and 215 . In block 214 , the content objects are identified to the migration system 178 . New versions of these content objects are obtained in block 215 and loaded onto the new computing device 124 rather than performing any transcoding.
A number of variations and modifications of the disclosed embodiments can also be used. For example, the above embodiments discuss using the license exchange for audio and video, but other embodiments are not to be limited in that way. Any content object that has DRM could be exchanged to a new program that has different DRM. For example, software or data could benefit from embodiments.
Specific details are given in the above description to provide a thorough understanding of the embodiments. However, it is understood that the embodiments may be practiced without these specific details. For example, circuits may be shown in block diagrams in order not to obscure the embodiments in unnecessary detail. In other instances, well-known circuits, processes, algorithms, structures, and techniques may be shown without unnecessary detail in order to avoid obscuring the embodiments.
Also, it is noted that the embodiments may be described as a process which is depicted as a flowchart, a flow diagram, a data flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process is terminated when its operations are completed, but could have additional steps not included in the figure. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination corresponds to a return of the function to the calling function or the main function.
Moreover, as disclosed herein, the term “storage medium” may represent one or more devices for storing data, including read only memory (ROM), random access memory (RAM), magnetic RAM, core memory, magnetic disk storage mediums, optical storage mediums, flash memory devices and/or other machine readable mediums for storing information. The term “machine-readable medium” includes, but is not limited to portable or fixed storage devices, optical storage devices, wireless channels, and/or various other mediums capable of storing, containing or carrying instruction(s) and/or data.
Furthermore, embodiments may be implemented by hardware, software, scripting languages, firmware, middleware, microcode, hardware description languages, and/or any combination thereof. When implemented in software, firmware, middleware, scripting language, and/or microcode, the program code or code segments to perform the necessary tasks may be stored in a machine readable medium such as a storage medium. A code segment or machine-executable instruction may represent a procedure, a function, a subprogram, a program, a routine, a subroutine, a module, a software package, a script, a class, or any combination of instructions, data structures, and/or program statements. A code segment may be coupled to another code segment or a hardware circuit by passing and/or receiving information, data, arguments, parameters, and/or memory contents. Information, arguments, parameters, data, etc. may be passed, forwarded, or transmitted via any suitable means including memory sharing, message passing, token passing, network transmission, etc.
Implementation of the techniques described above may be done in various ways. For example, these techniques may be implemented in hardware, software, or a combination thereof. For a hardware implementation the processing units may be implemented within one or more application specific integrated circuits (ASICs), digital signal processors (DSPs), digital signal processing devices (DSPDs), programmable logic devices (PLDs), field programmable gate arrays (FPGAs), processors, controllers, micro-controllers, microprocessors, other electronic units designed to perform the functions described above, and/or a combination thereof.
For a software implementation, the techniques, processes and functions described herein may be implemented with modules (e.g., procedures, functions, and so on) that perform the functions described herein. The software codes may be stored in memory units and executed by processors. The memory unit may be implemented within the processor or external to the processor, in which case the memory unit can be communicatively coupled to the processor using various known techniques.
While the principles of the disclosure have been described above in connection with specific apparatuses and methods, it is to be clearly understood that this description is made only by way of example and not as limitation on the scope of the disclosure. | A content distribution system for transporting audio or video licenses between content players that use digital rights management (DRM) is disclosed. The content distribution system includes at least a second license repository and an authentication engine. The second license repository receives second information describing a second plurality of content licenses. A first license repository stores a first plurality of content licenses. The first plurality of content licenses enable use of a plurality of content objects with a first content player within confines of DRM. The second license repository is geographically distant from the first license repository. The authentication engine authorizes the second plurality of content licenses of the second license repository. The second plurality of content licenses enable use of the plurality of content objects with the second content player within the confines of DRM. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an air conditioner, and more particularly to methods and systems for assembling an indoor unit of an air conditioner.
[0003] 2. Description of the Prior Art
[0004] Generally, industrial products such as an indoor unit of a dual-unit type air conditioner are made by separately manufacturing the parts thereof and then assembling the unit elements.
[0005] The process for assembling the products is performed on a linear conveyor system in consideration of manufacturing productivity thereof and convenience in supervising.
[0006] Such a conveyor system employs a method which a plurality of workers positioned along the linear conveyor line assemble the elements conveyed thereon.
[0007] An example of such a linear conveyor system is shown in FIG. 1 which shows a linear conveyer system on which elements of an indoor unit of a dual-unit type air conditioner are assembled.
[0008] As shown, a plurality of workers W are positioned along a long linear assembly line 1 in order to assemble elements of respective units. Opposite to the workers W, a kit box conveying line 2 is disposed. The kit box conveying line 2 functions to convey kit boxes containing elements of respective units along the assembly line 1 .
[0009] An inspection section 3 for performing quality testing upon the assembled units is positioned at the rear end of the assembly line 1 . A packing section 4 for packing the assembled indoor units so as to ship the same is positioned at a rear end of the inspection section 3 .
[0010] Thus, as kit boxes containing the elements of respective units are conveyed along the kit conveying line 2 , workers positioned along the assembly line 1 assemble the elements of respective products. Fully assembled indoor units now undergo the quality testing processes such as a withstand voltage test, a noise test, etc. Then the indoor units are packed at a packing section 4 so as to be shipped.
[0011] As described, in the linear conveyor line for manufacturing the indoor unit, a variety of unit processes are performed by the workers. As shown in FIG. 1, twenty-one workers for assembling the indoor unit, three workers for quality tests, and six workers for packing are required. Approximately, forty workers are required for respective processes including a supporting work force such as supervisors, repairmen, etc.
[0012] Accordingly, the linear conveyor system is very efficient in manufacturing products if workers are skilled ones.
[0013] There is, however, a drawback in that only one kind of product can be manufactured on such a linear conveyor system.
[0014] More specifically, if the manufacturer wants to assemble various kinds of products at the same time, the assembly systems corresponding thereto must be equipped, or the assembly line must be changed in accordance with the need of the manufacturer.
[0015] Recent trends require that a system capable of manufacturing multiple kinds of products in small quantity is preferred, so the assembly line must be changed quite often in order to meet the varying demands of consumers.
[0016] Consequently, a lot of time and funds must be spent on the manufacturing equipments, and manufacturers achieve relatively low productivity compared with the investment they have made. Even more, once the equipment is changed, then the equipment cannot be adopted in manufacturing products which have been previously produced. This means that the manufacturer cannot flexibly deal with the various demands of the customers.
SUMMARY OF THE INVENTION
[0017] An object of the present invention is to provide a system for assembling an indoor unit of an air conditioner in which a variety of products are conveniently manufactured in accordance with the demands of a market.
[0018] Another object of the present invention is to provide a method for assembling an indoor unit of air conditioner performed by the above-described assembly system.
[0019] To achieve the above object, the present invention provides a system for assembling indoor units of dual-unit type air conditioner, the system comprising: an evaporator assembly section for assembling evaporators; and a plurality of unit cells on which evaporators assembled on the evaporator assembly section are assembled with other elements so that indoor units are fully assembled, and inspection and packing processes of indoor units are performed.
[0020] It is preferable that said unit cell comprises: a rear body input section for inputting the indoor unit to which rear bodies and elements thereof are assembled; an evaporator fixing section for fixing evaporators assembled at the evaporator assembly section on the indoor units input to the rear body input section; a wiring section for wiring the indoor units assembled at the evaporator fixing section; a front panel fixing section for fixing front panels on the indoor units wired at the wiring section; an inspection section for testing quality of the indoor units fully assembled at the front panel fixing section; and a packing section for packing and shipping the indoor units which have passed the quality test at the inspection section.
[0021] To achieve another object of the present invention, the present invention provides a method for assembling indoor units of dual-unit type air conditioner, the method comprising the steps of: assembling evaporators; completing assembly of the indoor units by assembling evaporators with other elements; performing quality test upon the indoor units; and packing the indoor units which have passed the quality test.
[0022] Preferably, the step of completing comprises the steps of: inputting the indoor units on which rear bodies and other elements are assembled; fixing evaporators to the indoor units; wiring the indoor units; and fixing front panels to the indoor units. It is possible to further comprise the steps of stocking a plurality of elements in a kit box, and conveying the kit box.
[0023] According to the present invention, indoor units are respectively assembled, tested, and packed on separate unit cells. Therefore, the manufacturer can meet the varying demands of the market simply by adjusting the number of unit cells.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The above discussed object and advantages will be more apparent by from the following detailed description of preferred embodiments of the present invention with reference to the reference drawing accompanying, in which:
[0025] [0025]FIG. 1 is a schematic top plan view showing a conventional linear conveyor system on which indoor units of a dual-unit type air conditioner are manufactured;
[0026] [0026]FIG. 2 is a schematic top plan view of a floor of a manufacturing facility showing a system for assembling indoor units of a dual-unit type air conditioner according to a first embodiment of the present invention;
[0027] [0027]FIG. 3 is a schematic top plan view showing unit cell shown in FIG. 2 in greater detail;
[0028] [0028]FIG. 4 is a flow chart showing a method for assembling indoor units of dual-unit type air conditioners according to the first embodiment of the present invention;
[0029] [0029]FIG. 5 is a schematic top plan view showing a unit cell of a system for assembling indoor units of dual-unit type air conditioners according to a second embodiment of the present invention; and
[0030] [0030]FIG. 6 is a flow chart showing a method for assembling indoor units of dual-unit type air conditioners according to the second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0031] First, an assembly system for producing indoor units of dual-unit type air conditioners according to a first embodiment of the present invention will be described with reference to FIG. 1.
[0032] As shown, the assembly system of indoor units of a dual-unit type air conditioner according to the first embodiment of the present invention includes an evaporator assembly section 11 for assembling evaporators. The assembly system also has three unit cells U to which evaporators assembled at the evaporator assembly section 11 are sent and assembled together with other elements to form the indoor units. The assembled indoor units undergo quality testing and are packed at the cell units U.
[0033] On the evaporator assembly section 11 , elements of the evaporators are prepared, assembled by welding, and the assembled evaporators are inspected (i.e., quality tested).
[0034] [0034]FIG. 3 shows the unit cell U in greater detail. The unit cell U includes a rear body input section 12 , an evaporator fixing section 13 , a wiring section 14 , a front panel fixing section 15 , a kit box conveying section 16 , an inspection section 17 , and a packing section 18 .
[0035] The sections for manufacturing the indoor units, which comprises the rear body input section 12 , the evaporator fixing section 13 , the wiring section 14 , and the front panel fixing section 15 constitute individually drivable conveyors disposed on modules that are joined serially.
[0036] Quality tests are performed at the inspection section 17 which is positioned downstream of the front panel fixing section 15 . The packing section 18 is positioned at the rear end of the inspection section 1 7 . The kit box conveying section 16 extends from a front side of the rear body input section 12 to the front panel fixing section 15 . Kit boxes containing elements of respective units are loaded on the kit conveying section 16 and conveyed from the rear body input section 12 to the front panel fixing section 15 .
[0037] Described below is a method of assembling indoor units for dual-unit type air conditioners according to the first embodiment of the present invention.
[0038] Evaporators that have been assembled and inspected at the evaporator assembly section 11 . (Step S 11 in FIG. 4). Three workers W are positioned for the those processes.
[0039] Initially on the unit cells U, elements of indoor units are stocked in each kit box at the kit box conveying section 16 , and one worker W is positioned therefor (Step S 12 ). Elements stocked on the kit box are then conveyed on the kit conveying section 16 alongside unit cell U from the rear body input section 12 to the front panel fixing section 15 . Albeit not shown in the figures, kit boxes conveyed to the front panel fixing section 15 are returned to an input section of the kit conveying section 16 manually, or by separate means therefor.
[0040] Elements stocked in the kit box are assembled at the rear body input section 12 (Step S 13 ), e.g. to make an initial structure having a rear body of an indoor unit.
[0041] The initial structure assembled at the section 12 are conveyed to the evaporator fixing section 13 . Evaporators previously assembled at the evaporator assembly section 11 are now fixed on those structures (Step S 14 ).
[0042] Intermediate structures containing the evaporators are then wired at the wiring section 14 (Step S 15 ).
[0043] After the wiring process, the front panels are fixed on the intermediate structures at the front panel fixing section 15 (Step S 16 ), whereupon the indoor units are completely assembled.
[0044] Fully assembled indoor units are conveyed to the inspection section 17 where they undergo a plurality of quality testing processes such as a withstand voltage test, a noise test, etc. (Step S 17 ).
[0045] Indoor units that have passed the quality testing processes are then packed on the packing section 18 and shipped (Step S 18 ).
[0046] Each of Steps S 12 through S 18 is performed by one respective worker W, respectively. Accordingly, seven workers W 12 -W 18 are positioned along one unit cell U. If three units U are employed, then twenty-one workers are positioned along three unit cells U in all. Also, three workers W are positioned along the evaporator assembly section 11 . Thus, twenty-eight workers W are required in total. Taking supporting work force into account, e. g., forklift drivers, supervisors, repairmen, etc., approximately thirty-two workers are required for the whole processes.
[0047] According to the first embodiment of the present invention, all the processes are separately performed on separate sections. Thus, less workers are required in the manufacturing system of the present invention than the same of related art in which all the processes are performed on one linear conveyor line.
[0048] Also, since indoor units are separately assembled on respective unit cells, the manufacturer can flexibly deal with the varying demands of the market. That is, one kind of indoor unit can be manufactured on all three unit cells, or different kinds of indoor units can be respectively manufactured on three unit cells. Also, if there is a demand for one kind of indoor unit in small quantities, the manufacturer can operate one unit cell therefor while stopping other two unit cells, so that the work force can be put into the other operations.
[0049] By adjusting a number of unit cells allotted in manufacturing respective models according to what is required, the manufacturer can flexibly deal with varying demands of the market.
[0050] Although the described first embodiment of the present invention depicts one evaporator assembly section 11 and three unit cells U, the number thereof can be varied in accordance with the need of the manufacturer.
[0051] [0051]FIG. 5 shows a unit cell of a system for assembling indoor units of air conditioner according to a second embodiment of the present invention.
[0052] The indoor unit assembly system according to the second embodiment of the present invention comprises three unit cells U′, only one of which is depicted in FIG. 5. Unlike the first embodiment, an evaporator assembly section 21 is included in each of the unit cells U′.
[0053] The unit cells U′ comprises an evaporator assembly section 21 , a rear body input section 22 , an evaporator fixing section 23 , a wiring section 24 , a front panel fixing section 25 , an inspection section 26 , and a packing section 27 .
[0054] Indoor units are sequentially assembled at the evaporator assembly section 21 , the rear body input section 22 , the evaporator fixing section 23 , the wiring section 24 , and the front panel fixing section 25 . Fully assembled indoor units undergo quality testing processes at the inspection section 26 , and indoor units that have passed the quality testing processes are packed at the packing section 27 and shipped.
[0055] As described, the second embodiment of the present invention is constructed in a similar manner as that of the first embodiment of the present invention. The unique aspect of the second embodiment of the present invention is as follows. The evaporator assembly section 21 is included in the unit cells U′ instead of being separately positioned as in the first embodiment. The kit conveying section (designated by a reference numeral 16 in FIG. 4) for conveying kit boxes containing elements for making indoor units is excluded in the second embodiment. Instead those elements are stocked in parts areas C adjacent to the respective sections where assembly processes are performed.
[0056] According to the second embodiment of the present invention, each of the cell units is U-shaped, wherein the evaporator assembly section 21 and packing section 27 face each other. Accordingly, the space occupied by each cell unit according to the second embodiment is lessened by about 15% compare to the linear unit cells U of the first embodiment.
[0057] The method of assembly indoor units according to the second embodiment of the present invention is as follows.
[0058] First, evaporators are assembled at the evaporator assembly section 21 of unit cells U′ (Step S 21 ). Unlike the first embodiment, only one worker W performs the evaporator assembly process, since that worker only has to make enough evaporators to supply one cell unit.
[0059] Next, rear bodies are assembled at the rear body input section 22 , so that the indoor units start to be assembled (Step S 22 ).
[0060] Then, the rear bodies and the evaporators are conveyed to the evaporator fixing section 23 , where the evaporators are assembled to the rear bodies (Step S 23 ).
[0061] Then the wiring is performed at the wiring section 24 (Step S 24 ).
[0062] After the wiring process, front panels are installed at the front panel fixing section 25 (Step S 25 ), whereupon the indoor units are completed.
[0063] The fully assembled indoor units are now conveyed to the inspection section 26 , wherein the indoor units go through quality testing processes such as a withstand voltage test, noise test, etc. (Step S 26 ).
[0064] Indoor units that have passed the quality tests are conveyed to the packing section 27 where the indoor units are packed and shipped (Step S 27 ).
[0065] Each of Steps S 21 thorough S 27 is activated by one respective worker W. Accordingly, seven workers W are positioned at one unit cell U′, so twenty-one workers W at all are positioned at all three unit cells U′.
[0066] As in the first embodiment of the present invention, the indoor units are assembled on three unit cells by a few workers in the second embodiment. Thus, the manufacturer can flexibly adjust the amount of products produced in accordance with the varying demands of the market.
[0067] As described, indoor units are separately assembled, tested, and packed on respective unit cells. Accordingly, by adjusting the number of unit cells allotted to respective models, the manufacturer can flexibly deal with the variation in the number of products produced.
[0068] While the present invention has been particularly shown and described with reference to the preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and details may be effected therein without departing from the spirit and scope of the invention as defined by the appended claims. | Indoor air conditioner units are manufactured by pre-assembling evaporators and supplying the evaporators to a plurality of unit assembling stations, whereby at each unit assembling station, the evaporators are assembled with other air conditioner elements to form finished indoor air conditioner units. The evaporators can be assembled at an evaporator assembling station which supplies all of the unit assembling stations with evaporators. Alternatively, the evaporators can be assembled at each of the unit assembling stations. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to a process for fabrication of ytterbium (Yb) doped optical fiber through vapor phase doping technique. More particularly, the invention relates to fabrication of Yb/Al doped optical fiber by vapor phase deposition technique.
BACKGROUND OF THE INVENTION
[0002] Rare earth (RE) doped optical fibers has found promising applications in the field of optical amplifiers, fiber lasers and sensors. The RE elements doped into the core of such fibers act as the active medium. Different REs like Er, Nd, Yb, Sm, Ho and Tm can be doped to get lasing and amplification covering a wide range of wavelengths. RE doped fiber lasers are replacing gas based or solid state lasers in most of the applications due to their compactness, excellent beam quality and easy handling capability. As a result, there has been around 16% market growth of fiber laser with the overall sales touched $1.35 billion for the year 2012 as reported by Industrial Laser Solutions. Fiber laser devices are suitable for a variety of applications viz. material processing (cutting, grinding and engraving), range finding, medical and military applications. Thus fabrication of RE doped fibers with varied designs, compositions and appropriate RE concentration attracts a lot of research interest. The improvement in the properties of the fibers and increase in the process reproducibility remain the prime objective.
[0003] Reference may be made to U.S. Pat. No. 4,826,288 (1989) by R. J. Mansfield, B. C. McCollum, R. P. Tumminelli, “Method for fabricating optical fibers having cores with high rare earth content” wherein, the Modified chemical vapor deposition (MCVD) process with vapor phase chelate delivery technique is adopted for incorporation of high RE ions at the core of the fiber. The core layer deposition was done with silica along with refractive index raising dopant like Al 2 O 3 and RE oxides like Nd 2 O 3 or Yb 2 O 3 and Er 2 O 3 . Al 2 Cl 6 and RE(thd) 3 served as Al and RE incorporating agent respectively. Helium used as carrier gas of Al and RE compounds. The sources of RE vapor made of glass columns which were filled with solid RE-chelates along with an inert compound such as granulated high purity SiO 2 or Al 2 O 3 . The columns were heated upto a maximum temperature of 200° C. The temperature of transport line for Nd(thd) 3 was in the range of 210° C.-225° C. Various gaseous components were delivered to the reaction zone approximately 250° C., at most. The preferred concentrations of materials in the glass core were: 2-20 wt % of Al 2 O 3 , 0.1-4 wt % of Nd 2 O 3 and remainder being SiO 2 glass. Another fiber also made with combination of Yb 3+ and Er 3+ ions. Total RE 2 O 3 concentration was in excess of 5 wt %.
[0004] Drawbacks: - They believe to have RE content in the core of preform of about 0.1 to 10 Wt % or more. But in claim part, they only claim about 0.5 wt % of RE 2 O 3 . Nothing is said about the length of the preform and distribution of the dopants in the longitudinal as well as the radial direction.
[0005] Reference may be made to U.S. Pat. No. 5,961,682 (1999) by Yong-woo Lee, A. N. Guryanov, V. F. Khopin, D. D. Gusovsky, “Method of fabricating optical fiber doped with rare earth element using volatile complex” wherein, reaction of volatile RE-chelate compounds with SiCl 4 and O 2 took place. The surface of the tube was heated and water cooled to deposit porous core layer on which Al 2 Cl 6 or SiF 4 vapors absorbed. Volatile organic metal ligand composed of tris-cyclopentadienyl or tris-isopropylcyclopentadienyl compound of metal ions Er, Dy or Yb used for RE incorporation. Organic ligand bubbler temperature varied in the range of 150-300° C. while Al 2 Cl 6 bubbler temperature was in the range of 140-150° C. Freon gas was used to reduce OH content in the fiber. The difference in the refractive index between cladding layer and core layer greater than 0.025 achieved.
[0006] Reference may be made to U.S. Pat. No. 6,474,106 B1 (2002), by C. E. Crossland, Gang Qi, “Rare earth and Alumina-doped optical fiber preform process” wherein, an OVD process has employed to deposit porous soot core layer of SiO 2 —GeO 2 —Al 2 O 3 —Er 2 O 3 and then cladding layer employed on it as soot-on-soot process and then consolidation of the soot was done following soot-on-glass process in which the mandrel moved leaving a hollow, cylindrical soot blank core. The soot blank core was then consolidated and sintered in certain steps, to form a core rod known as cane. The temperature of solid AlCl 3 containing sublimator was varied preferably in between 150° C.-170° C. with Helium/Argon flow rates of about 0.5 to 0.7 slm to incorporate various concentration of Al 2 O 3 in the final preform. Er containing precursors, such as Er(FOD) 3 or Er(C 30 H 30 F 21 O 6 ) 3 , were heated in a bubbler to a temperature range of 130° C.-200° C. Higher Al containing preforms were reported as inclusions free. Er 2 O 3 concentration was around 500 ppm in each preform but concentrations of GeO 2 and Al 2 O 3 were varied in between 10 to 20 wt % and 2 to 10 wt % respectively.
[0007] Reference may be made to US Patent No. US 2005/0276555 A1 (2005) by T. Haruna, S. Ishikawa, T. Tam, T. Katayama, N. Taira, “Glass-body-producing method and optical glass body and optical fiber” wherein, an organometallic compound is heated from the outside into a glass pipe so that it decomposed into an organic constituent and metallic constituents upstream of the reaction zone. The organic part condensed and deposited there and the metallic part oxidized and deposited with glass layer. The decomposition performed by thermal -decomposition or photo-decomposition by using heat source or light source at temperature 100° C.-1000° C. During consolidation step Cl 2 gas was used for dehydration purpose to reduce the OH content. The OH content in the glass body had been reduced to 10 ppm, even at most 1 ppm.
[0008] Reference may be made to R. P. Tumminelli, B. C. McCollum, E. Snitzer, Journal of light wave Technology, Vol. 8, No. 11, (1990) pp. 1680-1683, “Fabrication of high concentration rare earth doped optical fibers using chelates” wherein, an individual AlCl 3 delivery line and three separate sources of RE-chelates were used. The RE-chelate columns were heated individually to the temperature in between 150 to 210° C. Carrier gas Helium was preheated and passed through RE and Al columns and delivered to a rotating mechanical seal via a heated delivery system. RE, Al and other reactants kept separated to prevent prereaction in the heated delivery tube. A ribbon burner was provided throughout the entire length prior to the reaction zone. The fiber containing 11 wt % Yb 2 O 3 and 0.2 wt % Er 2 O 3 had been prepared. Another fiber containing 1.0 wt % of Nd 2 O 3 had base losses <10 dB/kin at 1130 nm. For high concentration fiber base loss was around 150 dB/km at 1064 nm at 80° C. with OH concentration in between 15 to 20 ppm.
[0009] Drawbacks:—Nothing is said about the length of the preform and the distribution of the dopants in the longitudinal as well as the radial direction. For high concentration fibers, background loss and OH concentration is much higher.
[0010] Reference may be made to S. D. Jackson, T. Ryan, S. Mossman, Optics Communications, Vol. 216, (2003) pp. 401-404, “High power Tm +3 -doped silica fibre laser fabricated using chelate delivery deposition” wherein, a single dopant chamber contained a mixture of Tm 3+ and Al 3+ chelate which was heated to 200° C. and the vapor is entrained in the flow of O 2 , helium and other precursor materials. Then oxidation and deposition as porous layer took place which dried using Cl 2 gas. The layer then sintered and collapsed in usual manner. The double-clad fiber had a ˜12 μm core diameter with NA of 0.19. Tm 3+ concentration was of ˜0.35 wt % and background loss of <10 dB/km at 1300 nm.
[0011] Drawbacks:—Concentration level is significantly lower than that already achieved by solution doping method. The chelate heating system was not optimized and the process was limited to be batch type, using only 0.3 gm of chemical. They expect lower background losses but value is not mentioned.
[0012] Reference may be made to E. H. Sekiya, P. Barua, K. Saito, A. J. Ikushima, Journal of Non-Crystalline solids, Vol. 354, (2008) pp. 4737-4742, “Fabrication of Yb-doped silica glass through the modification of MCVD process” wherein, Yb(DPM) 3 furnace temperature was varied in the range of 200-250° C., but AlCl 3 furnace temperature was kept fixed at 130° C. Temperature of the delivery lines including that of SiCl 4 and other gaseous components were kept higher than the temperature of the Yb furnace to avoid condensation of precursor material in the nozzle part. Deposition conditions such as deposition temperature, SiCl 4 flow and burner speed was fixed to 1950° C., 0.6 g/min and 145 min/min respectively. Yb 3+ concentration obtained for only Yb-doped runs was in the range of 0.15-1.2 wt % while Yb 3+ concentration for Yb and Al doped runs was maximum of 0.7 wt % with Al 3+ concentration around 0.4 wt %. The variation in refractive index was of ±5% in the longitudinal direction and ±10% in the radial direction.
[0013] Drawbacks:—Soot layer deposition took place over a length of 550 mm of silica tube. But uniform core diameter and dopant distribution obtained in a preform of length of only 300 mm. Yb 3+ concentration is much lower compared to conventional method. SiCl 4 and other gases delivered from normal MCVD gas cabinet also have to send at higher temperature than Yb furnace, otherwise dopants will get condensed in the concentric nozzle part. Variation in dopant distribution in radial direction is around ±10%.
[0014] Reference may be made to B. Lenardic, M. Kveder, Optical society of America, OSA/OFUNFOEC 2009, “Advanced vapor-phase doping method using chelate precursor for fabrication of rare earth-doped fibers” wherein, the precursor vapors volatized at temperatures between 100° C.-220° C. and transported to the reaction zone by a system of heated conduits, specially constructed high-temperature rotary seal and sliding precursor vapor injection tube. Instead of burner MCVD is equipped with an induction furnace. Two different designs of sublimator used, bulk sublimator and flat bed sublimator. Flow rate of O 2 through SiCl 4 bubbler was set to 100 to 250 sccm at bubbler temperature of 35° C. with carriage traversed speed of 100 mm/min. Collapsing was comparatively faster as higher amount of heat supplied by induction furnace. Relationship evaluated between evaporation rate of Yb-chelate and final Yb 2 O 3 concentration in the fiber and evaporation rate of AlCl 3 with AlCl 3 sublimator temperature. One preform with Er 3+ concentration of 2680 ppm and Al 3+ concentration of 4900 ppm and another preform with Yb 3+ concentration of 31300 ppm and Al 3+ concentration of 12000 ppm have been fabricated.
[0015] Drawbacks:—Soot layer deposition took place over a length of 600 mm of silica tube. But final preform of length obtained of about 250-350 mm. Larger diameter of substrate tube (30/27 or 25/22) was compulsory to permit sliding injection tube into the substrate tube. Only 20 core layer can be deposited. From the refractive index profiles of the preforms, it is clear that the preforms having high center dip and variation in dopant concentration in radial direction.
[0016] Reference may be made to J. Sahu et. al., Optical society of America, OSA/CLEO/QELS 2010, “Rare-earth doped optical fiber fabrication using novel gas phase deposition technique” wherein, the chelate compound was heated in a crucible directly within the MCVD structure which is placed in a non-rotating tube close to the deposition zone. The crucible can be heated upto 800° C. and allowing inert gas to flow down the non-rotating tube and carry the generated vapors to the reaction zone while SiCl 4 and other dopants are added to the rotating part of the outer tube. High level of Al incorporated to give NA of 0.24 with base loss ˜3 dB/km. Yb 3+ concentration of 9000-20000 ppm-wt was achieved by adjusting crucible temperature with the base loss in the range of 30-70 dB/km. Core diameter of the fabricated fiber was 20 μm (overall fiber diameter 125 μm).
[0017] Drawbacks:—As Helium passes through the crucible, it will carry the vapors generated at the upper surface of the crucible. So evaporation rate of RE-chelate compound will be dependent of exposed surface area. It will be problematic to incorporate two or more RE compounds simultaneously.
[0018] Reference may be made to U.S. Pat. No. 5,474,588 (1995) by D. Tanaka, A. Wada, T. Sakai, T. Nozawa and R. Yamauchi, “Solution doping of a silica with erbium, aluminium and phosphorus to form an optical fiber” wherein a manufacturing method for Er doped silica is described in which silica glass soot is deposited using VAD apparatus to form a porous soot preform, dipping the said preform into an ethanol solution containing an erbium compound, an Al compound and a phosphoric ester, and desiccating said preform to form Er, Al and P containing soot preform. The desiccation is carried out for a period of 24-240 hours at a temperature of 60 to 70° C. in an atmosphere of nitrogen gas or inert gas. This desiccated soot preform is heated and dehydrated for a period of 2.5-3.5 hours at a temperature of 950 to 1050° C. in an atmosphere of helium gas containing 0.25 to 0.35% chlorine gas and further heated for a period of 3-5 hours at a temperature of 1400 to 1600° C. to render it transparent, thereby forming an erbium doped glass preform. The segregation of AlCl 3 in the preform formation process is suppressed due to the presence of phosphorus and as a result the doping concentration of Al 3+ can be set to a high level (>3 wt %). It has been also claimed that the dopants concentration and component ratio of Er, Al and P ions having extremely accurate and homogeneous in the radial as well as in longitudinal directions.
[0019] Reference may be made to U.S. Pat. No. 6,751,990 (2004), by T. Bandyopadhyay, R. Sen, S. K. Bhadra, K. Dasgupta and M. Ch. Paul, “Process for making rare earth doped optical fiber” wherein, unsintered particulate layer containing GeO 2 and P 2 O 5 core layer is deposited and doping by soaking the porous soot layer into an alcoholic/aqueous solution of RE-salts containing co-dopants like AlCl 3 /Al(NO 3 ) 3 in definite proportion is carried out. The porosity of the soot, dipping period, strength of the solution and the proportion of the codopants are controlled to achieve the desired RE 3+ concentration in the core and to minimize the core clad boundary defects. In subsequent steps drying, oxidation, dehydration and sintering of the RE containing porous deposit are performed followed by collapsing at a high temperature to produce the preform. The RE 3+ distribution in the resulting fiber matches with the Gaussian distribution of the pump beam to increase the overlapping and pump conversion efficiency.
[0020] The drawbacks of the above mentioned processes are as follows:
[0021] 1. Low concentration of dopant material as compared to conventional process;
[0022] 2. Decomposition and condensation of RE precursor materials occurred prior to reaction zone;
[0023] 3. Variation of dopant concentration along the longitudinal and radial direction of the preform;
[0024] 4. Shorter preform length due to loss in effective deposition zone;
[0025] 5. Process parameters are not optimized.
OBJECTS OF THE INVENTION
[0026] The main object of the present invention is to provide a process of fabrication of Yb doped optical fiber through vapor phase doping technique which obviates the drawbacks of the hitherto known prior art as detailed above.
[0027] Still another object of the present invention is to fabricate large core Yb 2 O 3 doped preform/fiber difficult to fabricate employing conventional solution doping process.
[0028] Another object of the present invention is to dope Yb 2 O 3 and Al 2 O 3 simultaneously with silica during formation of core layer for good homogeneity.
[0029] Yet another object of the present invention is to fabricate preform/fiber comprising of high concentration Yb 2 O 3 and Al 2 O 3 .
[0030] Another object is to increase effective preform length suitable for drawing long length of fiber.
[0031] Still another object of the present invention is to provide a method where the Yb 2 O 3 concentration uniformity along the longitudinal and radial direction of the preform/fiber core is superior to the hitherto known methods.
[0032] Yet another object of the present invention is to provide a method where the core-clad interface problem associated with high Al 2 O 3 doping level is eliminated.
[0033] Still another object of the present invention is to provide a reliable process of making large core Yb doped preform/fiber.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
[0034] FIG. 1 represents OFC-12MCVD system with high temperature vapor delivery unit.
[0035] FIG. 2 represents flowchart for fabrication of Yb doped optical fiber by the present invention.
SUMMARY OF THE INVENTION
[0036] Accordingly, present invention provides a process for fabrication of ytterbium (Yb) doped optical fiber through vapor phase doping technique, said process comprising the steps of:
[0037] (i) depositing pure silica cladding layers inside a silica glass substrate tube at a temperature in the range of 1900 to 1980° C. using Modified chemical vapor deposition (MCVD) process;
[0038] (ii) sublimating Aluminum(Al) salt and Yb-chelate in their respective sublimator chamber at a temperature in the range of 100 to 170° C. and 180 to 260° C. respectively to obtain Al-precursors and Yb-precursors;
[0039] (iii) introducing preheated inert carrier gas in the sublimator chamber of step (ii) at a flow rate in the range of 10 to 50 sccm for Al precursors and 100 to 300 sccm for Yb precursors;
[0040] (iv) transporting Al and Yb precursors with inert gas obtained in step (iii) to the substrate tube with the adjustment of temperature of ribbon burner in the range of 180-370° C.;
[0041] (v) passing O 2 gas into a SiCl 4 bubbler at a temperature in the range of 15 to 40° C. and a flow rate in the range of 80 to 150 sccm to transport SiCl 4 —O 2 gas mixture to the substrate tube;
[0042] (vi) mixing SiCl 4 , O 2 , Al precursors, Yb-precursors, and inert gas in the substrate tube followed by concurrent oxidation to form SiO 2 , Al 2 O 3 and Yb 2 O 3 ;
[0043] (vii) depositing a sintered core layer comprising SiO 2 —Al 2 O 3 —Yb 2 O 3 with targeted Al 2 O 3 and Yb 2 O 3 concentrations to obtain a deposited tube;
[0044] (viii) collapsing the deposited tube at a temperature in the range of 1900 to 2300° C. to obtain fabricated preform; and
[0045] (ix) drawing fibers from the fabricated preform obtained in step (viii) to obtain ytterbium (Yb) doped optical fiber.
[0046] In an embodiment of the present invention, 4-10 pure silica cladding layers are deposited in the substrate tube.
[0047] In yet another embodiment of the present invention, the temperature is in the range of 1910-1960° C.
[0048] In another embodiment of the present invention, the Al salt is AlCl 3 .
[0049] In yet another embodiment of the present invention, the sublimating temperature for Al salt is in the range of 120 to 160° C.
[0050] In yet another embodiment of the present invention, the Yb-chelate is Yb(thd) 3 .
[0051] In yet another embodiment of the present invention, the sublimating temperature for Yb-chelate is in the range of 200 to 240° C.
[0052] In yet another embodiment of the present invention, the inert carrier gas is helium.
[0053] In yet another embodiment of the present invention, the temperature of ribbon burner is in the range of 200-350° C.
[0054] In yet another embodiment of the present invention, the number of core layers is in the range of 1 to 40.
[0055] In yet another embodiment of the present invention, the temperature of deposition of sintered core layer is in the range of 1770 to 1920° C.
[0056] In still another embodiment of the present invention, the temperature of deposition of sintered core layer is in the range of 1820-1880° C.
[0057] In yet another embodiment of the present invention, the sintered core layer is deposited with a burner traverse speed in the range of 9 to 14 cm/min.
[0058] In yet another embodiment of the present invention, the NA (Numerical aperture) of the core glass is in the range of 0.06 to 0.32.
[0059] In yet another embodiment of the present invention, the Al 2 O 3 content of the fiber is in the range of about 0.5 to 18 mol %.
[0060] In yet another embodiment of the present invention, the Yb 2 O 3 concentration of the fiber is in the range of 0.2 to 2.0 mol %.
[0061] In still another embodiment of the present invention, Yb 2 O 3 concentration of the fiber is in the range of 0.25 to 1.25 mol %.
[0062] In yet another embodiment of the present invention, the collapsing temperature is in the range of 2050-2250° C.
[0063] In yet another embodiment of the present invention, the length of the fabricated preforms is up to 45 cm.
[0064] In yet another embodiment of the present invention, the core diameter of the fabricated fiber is in the range of 10 to 50 μm out of 125 μm overall diameter.
[0065] In still another embodiment of the present invention, the fabricated fiber exhibits uniform Yb distribution along the longitudinal as well as the radial direction of the preform/fiber with minimal core-clad interface problem.
[0066] In yet another embodiment of the present invention, variation of Al concentration at the two ends of the fabricated fiber is negligible.
[0067] In yet another embodiment of the present invention, variation in Yb concentration at the two ends of the fabricated fiber is less than <1%.
DETAILED DESCRIPTION OF THE INVENTION
[0068] The invention disclosed in the present specification provides a process for fabrication of Yb doped optical fiber through vapor phase doping technique which comprises:
(i) deposition of pure silica cladding layers inside a silica glass substrate tube to obtain matched clad type structure; (ii) evaporating anhydrous Al-salt and Yb-chelate by heating them in their respective sublimator chamber; (iii) introducing heated inert gas to transport vapors of Al-salt and Yb-compound to the substrate silica tube; (iv) passing O 2 gas into SiCl 4 bubbler to transport SiCl 4 —O 2 gas mixture to the substrate tube; (v) mixing of different transported gases viz. SiCl 4 —O 2 —AlCl 3 —Yb-chelate and inert gas into the substrate tube; (vi) concurrent oxidation of introduced vapors to form corresponding oxides viz. SiO 2 , Al 2 O 3 and Yb 2 O 3 ; (vii) deposition of sintered core layer comprising SiO 2 —Al 2 O 3 —Yb 2 O 3 with targeted Al 2 O 3 and Yb 2 O 3 concentrations at an appropriate temperature; (viii) collapsing of the tube in steps to obtain preform; and (ix) drawing of fibers from the preform.
[0078] The novelty of the present invention lies in fabrication of large core preform/fiber containing Yb 3+ and Al 3+ ions with superior longitudinal and radial uniformity and reduced core-clad interface problem due to which the fiber exhibits improved optical properties and better lasing performance.
[0079] In case of vapor phase doping technique, decomposition and condensation of Al and Yb-chelate compounds prior to the reaction zone resulting in variation of dopant concentration along the length of the preform are the two major problems. As a result, the process has not yet been adopted for commercial production.
[0080] In the present invention, the process parameters of the vapor phase doping technique have been optimized in such a way that Al and Yb-chelate compounds can be transported to the reaction zone without decomposition and condensation of precursor materials. Thus variation of dopants concentrations along the length and radial direction of the preform, have been minimized and deposition of more than forty core layers without any problem have also been achieved with good repeatability. As deposition of Al 2 O 3 and Yb 2 O 3 takes place simultaneously in presence of silica during formation of core layer in vapor phase, core-clad interface problem has also been eliminated due to better distribution of dopants into silica network.
[0081] The inventive step lies in:
[0082] 1. Delivery of Al and Yb-chelate compounds in vapor phase without decomposition and/or condensation of the precursor materials prior to the reaction zone.
[0083] 2. Formation and deposition of Al 2 O 3 and Yb 2 O 3 simultaneously in presence of silica and/or other refractive index modifying dopants during core layer deposition, so that the dopants are easily incorporated into silica network.
[0084] 3. Main burner temperature has been optimized in such a way that complete sintering of the deposited layers takes place with negligible decomposition of the precursor materials, leading to enhanced process repeatability.
[0085] The present invention is illustrated in FIG. 1 of the drawing accompanying this specification. In the drawing, there is one Main Gas cabinet and one High Temperature cabinet. Main gas cabinet is used to deliver normal MCVD gases (SiCl 4 , GeCl 4 , He, O 2 ) while high temperature cabinet is used to supply solid Yb and Al precursor materials in vapor phase. There are three separate delivery lines; one is for normal MCVD gases delivered from main gas cabinet and other two are from high temperature cabinet to transport Al and Yb precursor materials separately. The delivery lines from high temperature cabinet as well as all the lines that pass through the rotary union are kept heated and then the mixture of gases and vapors enters the silica tube. There is one ribbon burner at the input end of the silica tube which provides sufficient temperature for the flow of Yb precursor materials without condensation; but the temperature is not so high that it could be decomposed.
[0086] The process starts with flame polishing of the pure silica tube (Type: Heraeus F-300, Size: 24/28 mm or 17/20 mm) at around 1800-1900° C. to remove defects on the inner surface of the tube. Then deposition of pure SiO 2 sintered layers takes place to form matched clad type geometry at a temperature range of 1900-1980° C. using normal MCVD technique. The dopant precursor materials of Al and Yb which are in solid form, sublimated and transformed into their respective vapor phase by heating within the sublimators at the temperature range of 100-170° C. and 180-260° C. respectively. Controlled amount of preheated inert gas, such as Helium is added to the respective sublimator at the flow rates of 10-50 sccm for Al and 100-300 sccm for Yb respectively. Vapors of Al and Yb precursor materials are transported to the reaction zone by a system of highly heated delivery lines with temperature above 200° C., one high-temperature rotary union (temperature >200° C.) and one ribbon burner at the input end of the silica tube. The temperature of the ribbon burner is adjusted in such a way that the decomposition and/or condensation of the dopant precursor materials do not take place at the upstream end of the main burner. Controlled amount of O 2 is added to the SiCl 4 bubbler (maintained at a temperature varying in between 15-40° C.) at the flow rates of 80-150 sccm to supply SiCl 4 —O 2 gas mixture to the reaction zone. The deposition of Al 2 O 3 and Yb 2 O 3 takes place simultaneously in presence of silica through vapor phase doping technique. The main burner temperature is adjusted to ensure complete sintering of the core layers with minimal decomposition of the RE compounds prior to the reaction zone. The sintered core layer deposition takes place at a temperature range of 1770-1920° C. with carriage traverse speed of 9-14 cm/min. About 1 to 40 core layers are deposited simultaneously to form large core preform. After completion of the deposition, the tube is collapsed in stepwise manner at a temperature between 1900-2300° C. to obtain the final preform. Fiber is drawn from the two ends of the preforms with diameter of 125±0.2 μm using a Fiber Drawing Tower. The fibers are characterized in order to determine their geometrical properties, numerical aperture (NA), Yb concentration and to estimate the variation in dopant concentrations over the length of the preforms. Yb concentration is estimated from the absorption peak at 915 nm determined by ‘cut-back’ method. The dopant concentrations were also evaluated by Electron Probe Micro Analysis (EPMA) to check the dopant uniformity.
[0087] The different steps of the process are as follows:
(i) deposition of pure silica cladding layers inside a silica glass substrate tube to obtain matched clad type structure; (ii) evaporating anhydrous Al-salt and Yb-chelate by heating them in their respective sublimator chamber; (iii) introducing heated inert gas to transport vapors of Al-salt and Yb-compound to the substrate silica tube; (iv) passing O 2 gas into SiCl 4 bubbler to transport SiCl 4 —O 2 gas mixture to the substrate tube; (v) mixing of different transported gases viz. SiCl 4 —O 2 —AlCl 3 —Yb-chelate and inert gas into the substrate tube; (vi) concurrent oxidation of introduced vapors to form corresponding oxides viz. SiO 2 , Al 2 O 3 and Yb 2 O 3 ; (vii) deposition of sintered core layer comprising SiO 2 —Al 2 O 3 —Yb 2 O 3 with targeted Al 2 O 3 and Yb 2 O 3 concentrations at an appropriate temperature; (viii) collapsing of the tube in steps to obtain preform; and (ix) drawing of fibers from the preform.
[0097] The inventive step lies in incorporation of Yb 2 O 3 and Al 2 O 3 simultaneously in combination with SiO 2 during formation of core layer so that the dopants are easily incorporated into silica network. The process provides good homogeneity with reduced chances of forming RE cluster. Compared to the known techniques, the present method also enables to fabricate larger core preforms with better longitudinal and radial RE uniformity and smooth core-clad boundary with no star like defects. There is also no central dip in the refractive index profile of the fiber. The resulting preform/fiber contains about 0.5 mol % to 18 mol % of Al 2 O 3 and about 0.1 mol % to 2.0 mol % of Yb 2 O 3 .
[0098] Thus, the present invention is directed to make large core Yb doped preforms with pre-determined NA to achieve the designed single mode or multimode configurations.
EXAMPLES
[0099] The following examples are given by way of illustration and therefore should not be construed to limit the scope of the present invention.
Example 1
[0100] Deposition of sintered silica cladding layer was carried out inside a high quality silica tube at a temperature of 1940° C. using MCVD process.
[0101] Deposition of sintered core layer (MCVD process) comprising SiO 2 —Al 2 O 3 —Yb 2 O 3 was carried out by maintaining the following parameters:
SiCl 4 bubbler temperature: 25° C. Oxygen flow rate through SiCl 4 bubbler: 120 sccm AlCl 3 sublimator temperature: 140° C. Helium flow rate through AlCl 3 sublimator: 20 sccm Yb(thd) 3 sublimator temperature: 220° C. Helium flow rate through Yb(thd) 3 sublimator: 200 sccm Deposition temperature: 1845° C. Carriage traverses speed: 12.5 cm/min Ribbon burner temperature: 280° C.
[0111] The collapsing was carried out in stepwise manner (4 forward collapsing steps at a temperature of 2060, 2130, 2175 and 2210° C. and a back collapsing at 2260° C.) to obtain the final preform.
[0112] The fiber was drawn from fabricated preform (length 400 mm) having the following specifications:
Core diameter: 12.0 μm out of 125 μm overall diameter NA: 0.12 Yb 2 O 3 concentration: 0.32 mol % Al 2 O 3 concentration: 2.6 mol % Variation in Yb concentration at the two ends of the preform: 0.8%
Example 2
[0118] Deposition of sintered silica cladding layer was carried out inside a high quality silica tube at a temperature of 1930° C. using MCVD process.
[0119] Deposition of sintered core layer (MCVD process) comprising SiO 2 —Al 2 O 3 —Yb 2 O 3 was carried out by maintaining the following parameters:
SiCl 4 bubbler temperature: 30° C. Oxygen flow rate through SiCl 4 bubbler: 90 sccm AlCl 3 sublimator temperature: 160° C. Helium flow rate through AlCl 3 sublimator: 25 sccm Yb(thd) 3 sublimator temperature: 230° C. Helium flow rate through Yb(thd) 3 sublimator: 140 sccm Deposition temperature: 1830° C. Carriage traverses speed: 12.0 cm/min Ribbon burner temperature: 295° C.
[0129] The collapsing was carried out in stepwise manner (5 forward collapsing steps at a temperature of 2045, 2090, 2125, 2160 and 2190° C. and a back collapsing at 2230° C.) to obtain the final preform.
[0130] The fiber was drawn from fabricated preform (length 350 mm) having the following specifications:
Core diameter: 20.0 μm out of 125 μm overall diameter NA: 0.20 Yb 2 O 3 concentration: 0.22 mol % Al 2 O 3 concentration: 7.7 mol %
Example 3
[0135] Deposition of sintered silica cladding layer was carried out inside a high quality silica tube at a temperature of 1945° C. using MCVD process.
[0136] Deposition of sintered core layer (MCVD process) comprising SiO 2 —Al 2 O 3 —Yb 2 O 3 was carried out by maintaining the following parameters:
SiCl 4 bubbler temperature: 20° C. Oxygen flow rate through SiCl 4 bubbler: 80 sccm AlCl 3 sublimator temperature: 130° C. Helium flow rate through AlCl 3 sublimator: 38 sccm Yb(thd) 3 sublimator temperature: 240° C. Helium flow rate through Yb(thd) 3 sublimator: 270 sccm Deposition temperature: 1860° C. Carriage traverses speed: 11.5 cm/min Ribbon burner temperature: 210° C.
[0146] The collapsing was carried out in stepwise manner ( 3 forward collapsing steps at a temperature of 2110, 2170 and 2210° C. and a back collapsing at 2255° C.) to obtain the final preform.
[0147] The fiber was drawn from fabricated preform (length 370 mm) having the following specifications:
Core diameter: 9.5 μm out of 125 μm overall diameter NA: 0.14 Yb 2 O 3 concentration: 0.85 mol % Al 2 O 3 concentration: 3.8 mol %
Example 4
[0152] Deposition of sintered silica cladding layer was carried out inside a high quality silica tube at a temperature of 1950° C. using MCVD process.
[0153] Deposition of sintered core layer (MCVD process) comprising SiO 2 —Al 2 O 3 —Yb 2 O 3 was carried out by maintaining the following parameters:
SiCl 4 bubbler temperature: 25° C. Oxygen flow rate through SiCl 4 bubbler: 130 sccm AlCl 3 sublimator temperature: 148° C. Helium flow rate through AlCl 3 sublimator: 12 sccm Yb(thd) 3 sublimator temperature: 200° C. Helium flow rate through Yb(thd) 3 sublimator: 160 sccm Deposition temperature: 1890° C. Carriage traverses speed: 10.5 cm/min Ribbon burner temperature: 330° C.
[0163] The collapsing was carried out in stepwise manner (5 forward collapsing steps at a temperature of 1980, 2040, 2090, 2150 and 2210° C. and a back collapsing at 2260° C.) to obtain the final preform.
[0164] The fiber was drawn from fabricated preform (length 420 mm) having the following specifications:
Core diameter: 40.0 μm out of 125 μm overall diameter NA: 0.11 Yb 2 O 3 concentration: 0.08 mol % Al 2 O 3 concentration: 2.3 mol % Variation in Yb concentration at the two ends of the preform: 1.7%
ADVANTAGES OF THE INVENTION
[0170] The main advantages of the present invention are:
[0171] 1. In-situ RE incorporation, free from any mechanical alteration problem during the preform fabrication run.
[0172] 2. Higher amount of dopants incorporation efficiency as compare to prior art.
[0173] 3. RE clustering problem is much lower as compared to other conventional preparation methods.
[0174] 4. The process provides smooth core-clad boundary, without generation of star-like defects which appear for high concentration of Al 2 O 3 doping in silica network.
[0175] 5. Fabrication of large core diameter in preform stage is possible to achieve.
[0176] 6. Uniform longitudinal and radial distribution of dopants in the core of fiber is also achievable.
[0177] 7. Larger preform length is achievable as compared to prior art.
[0178] 8. Process repeatability is much higher as compared to other conventional MCVD methods. | The present invention provides a process for fabrication of ytterbium (Yb) doped optical fiber through vapor phase doping technique. The method comprises deposition of Al2O3 and Yb2O3 in vapor phase simultaneously in combination with silica during formation of sintered core layer. This is followed by collapsing at a high temperature in stepwise manner to produce the preform and drawing of fibers of appropriate dimension. The process parameters have been optimized in such a way that Al and Yb-chelate compounds can be transported to the reaction zone without decomposition and condensation of precursor materials. Thus variations of dopants concentration along the length of the preform have been minimized to <1% and good repeatability of the process has also been achieved. The resulting fibers also have smooth core-clad boundary devoid of any star-like defect. The process can be reliably adopted for fabrication of large core Yb doped optical fibers. The fibers also show low loss, negligible center dip and good optical properties suitable for their application as fiber lasers. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to fuel recovery systems for internal combustion engines and more particularly to a recovery systems for the ethanol constituent of E85 fuel for use with internal combustion engines.
2. Description of the Prior Art
One of the very first sources of emissions targeted for reduction in internal combustion engines utilized in passenger cars and other motor vehicles was blow-by, i.e., air and unburned fuel that enters the crankcase and is emitted into the atmosphere by a breather vent in a valve cover.
Since the early 1960s, positive crankcase ventilation (PCV) systems have been utilized which collect and direct the unburned fuel to the carburetor or intake manifold where it is burned in the cylinders. These systems not only eliminated this source of pollution but also slightly improved fuel economy as they ensured that fuel that was previously lost by dispersal into the atmosphere was burned in the engine.
At normal engine operating temperatures, well above the volatilization temperatures of the various fractions of conventional hydrocarbon fuel, i.e., gasoline, fuel in the blow-by moves directly through the PCV system and there is no accumulation of fuel in the crankcase. However, at start-up and in low temperature operating conditions, the fuel will condense in the crankcase. As the engine warms up, this condensed fuel vaporizes and is swept through the PCV system. Because gasoline comprises many different hydrocarbon fractions that vaporize at different temperatures, this vaporization occurs gradually over a period of time.
Recently a low emission fuel manufactured from agricultural products, primarily corn, and designated E85 has become available for consumer use in passenger cars. The fuel is nominally 85% ethanol or grain alcohol. When an E85 fueled vehicle is started or operated in a low temperature environment, some of the ethanol enters the crankcase in liquid form and mixes with the engine lubricating oil. As the engine warms up and reaches 78 degrees Celsius (172.4 degrees Fahrenheit) all of the ethanol in the crankcase vaporizes and flows through the PCV system at a very high rate. Even though the oxygen sensor has shut off fuel flow to the cylinders, in extreme cases there may be so much vaporized ethanol flowing through the PCV system that the engine runs rich and exhaust emissions are increased. At the very least, this high momentary flow of vaporized ethanol through the PCV system and engine is difficult for the engine control system to compensate for. Additionally, this event may result in drivability issues.
From the foregoing, it is apparent that improvements in fuel systems for vehicles utilizing E85 as fuel are desirable.
SUMMARY OF THE INVENTION
A fuel recovery system for a single vaporization temperature fuel or fuel constituent such as ethanol of E85 fuel for motor vehicles includes a canister filled with an absorbent media such as activated charcoal. The canister includes an inlet in fluid communication with the crankcase blow-by vent of an internal combustion engine, an outlet in communication with the air intake manifold of the engine and a vent communicating with the atmosphere. Control valves may be incorporated into the system to control fluid flows. As ethanol that has been mixed with engine oil during startup and before the engine reaches operating temperature vaporizes when the oil reaches approximately 78 degrees Celsius, it is first absorbed in the activated charcoal and then slowly released and burned in the engine. The slow release and burning of the ethanol from the canister avoids a brief transient condition that may interfere with engine operation and increase emissions. A passive fuel recovery system is also disclosed.
Thus it is an object of the present invention to provide an apparatus for temporarily absorbing fuel such as ethanol from crankcase blow-by of an internal combustion engine.
It is a further object of the present invention to provide an apparatus for absorbing fuel such as ethanol from a crankcase of an internal combustion engine having a canister communicating with the blow-by vent of the engine and its intake manifold.
It is a still further object of the present invention to provide an apparatus for absorbing fuel such as ethanol from blow-by from a crankcase of an internal combustion engine and providing it to the engine intake manifold over a period of time.
It is a still further object of the present invention to provide an apparatus for temporarily absorbing fuel such as ethanol from blow-by from an internal combustion engine having a canister containing activated charcoal.
Further objects and advantages of the present invention will become apparent by reference to the following description and appended drawings wherein like reference numbers refer to the same component, element or feature.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of a first embodiment of an E85 ethanol or fuel recovery system associated with an internal combustion engine, and
FIG. 2 is a diagrammatic view of a second embodiment of an E85 ethanol or fuel recovery system associated with an internal combustion engine.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 , a fuel recovery system for an internal combustion engine is illustrated and designated by the reference number 10 . The system 10 is connected to and utilized in conjunction with an internal combustion engine 12 having an engine block 14 defining a plurality of cylinders 16 , a like plurality of pistons 18 connected to a crankshaft 22 , one or two cylinder heads 24 , one or more valve covers 26 and an intake manifold 28 .
The fuel recovery system 10 includes an oil separator 32 which may be connected to the interior of one or both of the valve covers 26 by a conduit, pipe or hose 34 . The oil separator 32 includes baffles 36 or other flow interrupting or redirecting structures which collect oil mist or droplets which have been carried by the blow-by flow from within the valve covers 26 . By virtue of its location above the valve covers 26 , oil that collects in the oil separator 32 flows back into the valve covers 26 and the engine 12 by gravity.
A second conduit, pipe or hose 38 provides a fluid pathway between the oil separator 32 and a recovery canister 40 . The recovery canister 40 may be any convenient regular or irregular shape such as cylindrical or rectangular and may be fabricated of, for example, a rugged plastic such as acrylonitrile-butadiene-styrene (ABS). The canister 40 is filled with an absorbent of E85 such as activated charcoal 42 or other suitable media. Preferably at the bottom of the canister 40 or, in any event, opposite the second, inlet pipe or hose 38 is an orifice or vent 44 which communicates with the atmosphere.
A third conduit, pipe or hose 46 communicates between the interior of the canister 40 and a solenoid control valve 48 . The control valve 48 is opened and closed by signals emanating from an engine control module 50 . The engine control module 50 is typically a microprocessor which includes inputs for signals from various engine and vehicle sensors (not illustrated) and controls various operating conditions and parameters of the engine 12 . For example, an engine temperature sensor 52 may be utilized to provide a data signal to the engine control module 50 regarding the current temperature of the engine 12 .
A fourth conduit, pipe or hose 54 provides a fluid pathway between the control valve 48 and the intake manifold 28 . A flow controller 56 which may be either an orifice having a predetermined size and thus flow rate or a second solenoid control valve controls flow from the fourth pipe or hose 54 to the interior of the valve covers 26 of the engine 12 .
The operation of the fuel recovery system 10 will now be described. For this description, it will be assumed that the engine 12 is fueled with E85 and is cold and at an ambient temperature which typically will be in the range of 20 degrees to 70 degrees Fahrenheit. Of course, depending upon the climate and season, temperatures may readily be encountered that are outside this range, sometimes substantially. When started in this condition, an engine 12 utilizing E85 fuel will experience blow-by of the fuel into the crankcase 22 and mixing of the E85 fuel and particularly the ethanol with the engine oil. The solenoid control valve 48 will preferably be closed at this time and the flow controller 56 , if it is a valve, will be open. This situation will continue until the engine 12 and, more specifically, the oil have reached a temperature of 78 degrees Celsius (172.4 degrees Fahrenheit).
At this point, the ethanol will begin to vaporize rapidly and blow-by containing ethanol will exit the valve covers 26 , enter the oil separator 32 where oil is removed from the blow-by and returned to the engine 12 and enter the recovery canister 40 where the ethanol is absorbed in the activated charcoal 42 . The vent 44 in the canister 40 allows flow of ethanol and air into the canister 40 from the valve covers 26 and exhaust of cleansed air into the atmosphere. Rather quickly, all of the ethanol will vaporize and be absorbed by the activated charcoal 42 , as described.
The engine operating temperature and the temperature of the engine oil will continue to rise. At a temperature well above 78 degrees Celsius, for example, 95 to 100 degrees Celsius (203 to 212 degrees Fahrenheit)or higher, the engine control module 50 or other controller will issue a command to open the solenoid control valve 48 and, if the flow controller 56 is a solenoid valve, issue a command to close it. In this operating condition, the partial vacuum in the intake manifold 28 will draw atmospheric air in through the vent 44 of the canister 40 which will absorb and carry with it ethanol from the activated charcoal 42 . This air and ethanol will then flow through the fourth pipe or hose 54 , be drawn into the intake manifold 28 and the cylinders 16 and be burned.
Over a period of time of normal driving, substantially all of the ethanol will be purged from the canister 40 . Thus, E85 or any other fuel having substantially a single vaporization temperature, will be absorbed in the activated charcoal 42 and then slowly returned or metered into the blow-by flow to the intake manifold 28 and the cylinders 16 where it is burned.
After an additional period of time, the solenoid control valve 48 may be closed and the flow controller 56 may be opened if it is a valve to allow blow-by from the engine 12 to flow directly from the valve covers 26 to the intake manifold 28 in accordance with conventional positive crankcase ventilation practice.
Referring now to FIG. 2 , a second embodiment of the fuel recovery system according to the present invention is illustrated and designated by the reference number 100 . The system 100 is quite similar to the first embodiment system 10 and is typically utilized with an internal combustion engine 12 having components as listed and described in FIG. 1 . Such description will therefore not be repeated. The system 100 may be fairly described as passive in that it includes a fresh air intake line 102 which communicates with a source of fresh air such as an air inlet duct 104 and the interior of the valve covers 26 . A positive crankcase ventilation (PCV) valve 106 in another one of the valve covers 26 feeds an outlet line or hose 108 which extends between the other one of the valve covers 26 (or the opposite end of the valve cover 26 if there is only one) and a canister 110 containing activated charcoal 112 . From the canister 110 , a return line or hose 116 extends to the intake manifold 28 .
The passive fuel recovery system 100 essentially operates continuously in the positive crankcase ventilation circuit of the engine 12 . As such, blow-by from the engine 12 constantly circulates through the line 106 and the activated charcoal 112 in the canister 110 , the flow being established by the partial vacuum in the intake manifold 28 and supplied by the fresh air inlet line 102 .
During warm up of the engine 12 utilizing E85 or other fuel having substantially a single vaporization temperature, the relatively sudden and significant flow of, for example, ethanol, will be absorbed in the activated charcoal 112 and then slowly returned or metered to the blow-by flow in the return line 116 to the intake manifold 28 and burned in the cylinders 16 of the engine 12 .
The description of the invention is merely exemplary in nature and 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. | A recovery system for fuel for motor vehicles includes a canister having an absorbent media such as activated charcoal. The canister includes an inlet in fluid communication with the blow-by vent of an internal combustion engine and an outlet in communication with the air intake manifold of the engine. Control valves may be incorporated into the system to control fluid flows. As a single vaporization temperature fuel or fuel constituent such as ethanol that has mixed with engine oil during startup vaporizes when the oil reaches its vaporization temperature, it is first absorbed in the activated charcoal and then slowly released and burned in the engine. The system has particular applicability to E85 fueled vehicles. | 5 |
This invention relates to a process for the production of alcohols from carboxylic acids. More specifically, this invention relates to a process for a conversion of carboxylic acids to carboxylic acid esters and the subsequent catalytic hydrogenation of these carboxylic acid esters to the corresponding alcohols. In addition the invention provides for the reduction of catalyst poisons through the use of carbon monoxide.
Some of the most important commercial alcohols are fatty alcohols obtained from natural sources. Producing these alcohols from carboxylic acids is very difficult because the reaction requires hazardous conditions of high pressure hydrogen and high reaction temperatures. Since demand for these alcohols has outstripped the natural supply, various means of producing these alcohols synthetically have been practiced.
The production of such alcohols is described in the literature in U.S. Pat. No. 1,839,974 which teaches a method for the direct catalytic reduction of carboxylic acids. This method depends upon the use of hydrogen for the removal of oxygen from the acid function in the form of water while still another molecule of hydrogen takes up the position of the oxygen atom removed. Thereafter, an esterification reaction occurs between a portion of the alcohol formed with a portion of the remaining acid. The hydrogenation catalyst is rapidly deactivated by the large amounts of acid present and this method produces water which is a catalyst poison and is known to have detrimental effects.
U.S. Pat. No. 2,965,660 teaches a process for the catalytic production of carboxylic acid esters by reduction of organic carboxylic acids using carbon monoxide or mixtures containing largely carbon monoxide in admixture with hydrogen. However, this process produces a "scatter" or broad range of organic materials because of the uncontrollability of the reaction. Therefore, materials other than the desired alcohols for any particular use are also produced and must be separated. British Pat. No. 783661 teaches producing fatty acid esters in the presence of a mixture of hydrogen and carbon monoxide using copper/chromium oxide as the catalyst. This reference teaches carbon monoxide as a poison and states the method taught to be effective in spite of the presence of carbon monoxide. Methanol is produced using the method.
The recognition of water as a catalyst poison is set forth in Chemical Abstracts 110746s, which teaches the use of an inert sweep gas to physically remove water from the high pressure hydrogenation of fatty acid esters. Further, the Journal of Catalysis, volume 5, 1966, pages 401 through 411 also teaches that water is a catalyst poison. In this reference it is proposed that carbon monoxide is produced by decomposition of methanol during the heating process and in turn promotes the catalyst. The reference teaches that in such a process water is surprisingly not a detriment.
These references are representative but non-exhaustive of the prior art which teaches in large part that carboxylic acid esters can be utilized to produce alcohols. However, as indicated by these references, the processes are detrimental in many respects including low catalyst activity, rapid catalyst degradation, high pressures and temperatures necessary to carry out the processes and uncontrollability of the products achieved. It would therefore be of great benefit to provide a process which is simple, requires more moderate conditions and produces alcohols of highly controllable molecular weight.
It has now been discovered in accordance with the present invention that alcohols can be produced from carboxylic acids utilizing a continuous catalyst-free acid process which comprises combining carboxylic acids with an alcohol in the presence of carbon monoxide to produce carboxylic acid esters and carbon dioxide, then combining the carboxylic acid esters so obtained with hydrogen and carbon monoxide over a standard hydrogenation catalyst to obtain alcohols of desired molecular weight.
The instant invention thus has many advantages over the prior art methods. No catalyst is utilized other than a standard hydrogenation catalyst. If desired, alcohol utilized to react with the carboxylic acids can be obtained directly from the product stream, thus tightly controlling the type of alcohols obtained. The use of hydrogen and carbon monoxide effectively removes water from the reaction, thereby eliminating side reactions and catalyst deactivation.
Catalyst life is additionally enhanced since acid does not contact the catalyst. Acid processes heretofore known suffered catalyst loss from degradation by the fatty acid feed. The instant invention avoids contact between the fatty acids and the hydrogenation catalyst. Water is chemically removed before contacting the catalyst to further extend catalyst life.
Thus in the first stage of the present invention carboxylic acids are combined with alcohols in the presence of carbon monoxide to produce carboxylic acid esters. The reaction proceeds by the continuous removal of water and the process is effective for both continuous and batch process applications. This invention is a distinct improvement to the prior art methods wherein acid or base catalysts are used at some point in the production of such carboxylic acid esters, followed by some method of neutralization or purification. U.S. Pat. No. 2,965,660 teaches a similar method but requires a catalyst, does not utilize alcohols as a feed and produces a "scatter" of products in contrast to the controlled process of the present invention. The present invention produces carboxylic acid esters without a catalyst in high yield with minimal handling or purification.
Once obtained, the carboxylic acid esters are hydrogenated to alcohols in high yield in either a continuous or batch process using reduced reaction conditions and a hydrogen feed gas containing carbon monoxide. This process is in distinct contrast to the well known acid methyl ester batchwise process which requires purification prior to hydrogenation. A second commercial process which is improved upon by the present invention involves combining a slurry feed of carboxylic acid, powdered catalyst and a large excess of an alcohol with a hydrogen feed gas and batch-type reactor.
Carboxylic acid starting materials of the present invention can be any acid capable of esterification and subsequent hydrogenation. In general, these acids have the general formula RCOOH wherein R is normally a branched or unbranched, saturated or unsaturated aliphatic group containing from 1 to about 28 carbon atoms. However, R can also be aromatic and can contain additional organic acid groups as exemplified by adipic acid, all of which will be esterified and subsequently reduced.
Representative but non-exhaustive examples of carboxylic acids useful in the practice of the present invention are
______________________________________C.sub.5 H.sub.11 COOH C.sub.17 H.sub.29 COOH HOOCCH.sub.2COOHC.sub.6 H.sub.13 COOH C.sub.18 H.sub.37 COOH HOOCCH.sub.2 CH.sub.2COOHC.sub.7 H.sub.15 COOH C.sub.19 H.sub.39 COOH HOOCCH.sub.2 CH.sub.2 CH.sub.2COOHC.sub.8 H.sub.17 COOH C.sub.19 H.sub.37 COOH HOOC(CH.sub.2).sub.4 COOHC.sub.9 H.sub.19 COOH C.sub.19 H.sub.35 COOH HOOC(CH.sub.2).sub.5 COOHC.sub.10 H.sub.21 COOH C.sub.19 H.sub.33 COOH HOOC(CH.sub.2).sub.6 COOHC.sub.11 H.sub.23 COOH C.sub.19 H.sub.31 COOH HOOC(CH.sub.2).sub.7 COOHC.sub.12 H.sub.25 COOH C.sub.19 H.sub.29 COOH HOOC(CH.sub.2).sub.8 COOHC.sub.13 H.sub.27 COOH C.sub.13 H.sub.25 COOH C.sub.20 H.sub.41 COOH C.sub.21 H.sub.43 COOH ##STR1##C.sub.14 H.sub.29 COOH C.sub.21 H.sub.41 COOHC.sub.15 H.sub.31 COOH C.sub.15 H.sub.29 COOH C.sub.21 H.sub.39 COOH C.sub.21 H.sub.37 COOH ##STR2##C.sub.16 H.sub.33 COOH C.sub.16 H.sub.35 COOH C.sub.21 H.sub.35 COOH C.sub.21 H.sub.33 COOH ##STR3##C.sub.17 H.sub.33 COOH C.sub.22 H.sub.45 COOH poly(acrylic acids)C.sub.17 H.sub.31 COOH C.sub.23 H.sub.47 COOH where n is the number of repetitive units, normally from about 10 to about 100,000, preferably 10 to about 1,000.______________________________________
The alcohol for the initial reaction of carbon monoxide with carboxylic acid to produce the carboxylic acid ester has the general formula R 2 OH wherein R 2 is normally an alkyl group containing from 1 to 30 carbon atoms. These alkyl groups may be linear or branched, and may contain one or more aromatic, or alcohol functions. These alcohols are most conveniently the product alcohols of the process, a small portion of which is utilized in the reaction with carboxylic acids.
Representative but non-exhaustive examples of alcohols useful in this invention are
______________________________________C.sub.5 H.sub.11 CH.sub.2 OH C.sub.6 H.sub.13 CH.sub.2 OH C.sub.21 H.sub.43 CH.sub.2 OH C.sub.21 H.sub.41 CH.sub.2 ##STR4##C.sub.7 H.sub.15 CH.sub.2 OH C.sub.8 H.sub.17 CH.sub.2 OH C.sub.21 H.sub.39 CH.sub.2 OH C.sub.21 H.sub.37 CH.sub.2 ##STR5##C.sub.9 H.sub.19 CH.sub.2 OH C.sub.21 H.sub.35 CH.sub.2 OHC.sub.10 H.sub.21 CH.sub.2 OH C.sub.11 H.sub.23 CH.sub.2 OH C.sub.21 H.sub.33 CH.sub.2 OH C.sub.22 H.sub.45 CH.sub.2 ##STR6##C.sub.12 H.sub.25 CH.sub.2 OH C.sub.23 H.sub.47 CH.sub.2 OH poly(alkyl alcohol)C.sub.13 H.sub.27 CH.sub.2 OH where n is number ofC.sub.13 H.sub.25 CH.sub.2 OH HOCH.sub.2 CH.sub.2 OH repetitive units normallyC.sub.14 H.sub.29 CH.sub.2 OH HOCH.sub.2 CH.sub.2 CH.sub.2 OH from about 1 to aboutC.sub.15 H.sub.31 CH.sub.2 OH HO(CH.sub.2).sub.4 OH 10,000 preferably fromC.sub.15 H.sub.29 CH.sub.2 OH HO(CH.sub.2).sub.5 OH 10 to 1,000.C.sub.16 H.sub.35 CH.sub.2 OH HO(CH.sub.2).sub.6 OHC.sub.17 H.sub.35 CH.sub.2 OH HO(CH.sub.2).sub.7 OHC.sub.17 H.sub.33 CH.sub.2 OH HO(CH.sub.2).sub.9 OHC.sub.17 H.sub.31 CH.sub.2 OH HO(CH.sub.2).sub.10 OHC.sub.17 H.sub.29 CH.sub.2 OHC.sub.18 H.sub.37 CH.sub.2 OH C.sub.19 H.sub.39 CH.sub.2 OH C.sub.19H.sub.37 CH.sub.2 OH C.sub.19 H.sub.35 CH.sub.2 OH C.sub.19 H.sub.33CH.sub.2 OH C.sub.19 H.sub.31 CH.sub.2 OH C.sub.19 H.sub.29 CH.sub.2 ##STR7## HO(CH.sub.2 CH.sub.2 O).sub.nH ethylene glycols wherein n is the number of repetitive units, normally from 1 to about 100, preferably 1 to about 30C.sub.20 H.sub.41 CH.sub.2 OH______________________________________
The combination of carboxylic acids with alcohols is normally carried out at temperatures of from about 200° C. to about 400° C. The invention is operable at lower temperatures than prior art processes but can, if desired for any reason, be carried out at these higher temperatures. This reaction can be carried out at a pressure of from 1 to 350 atmospheres but normally a pressure of from about 50 to about 300 atmospheres will be used.
The hydrogenation of the resultant carboxylic acid ester is normally carried out over hydrogenation catalysts well known to those skilled in this art. In general, hydrogenation catalysts include both metallic and metallic oxide compounds of transition elements in sub-group I such as copper, sub-group II such as zinc, sub-group VI such as chromium, sub-group VII such as manganese, and sub-group VIII such as iron. Support materials such as bentonite, Fuller's Earth, activated charcoal alumina and the like can be used. Representative but non-exhaustive examples of such catalysts are Cu-Fe-Al as described in U.S. Pat. No. 4,252,689, zinc chromate, copper chromite, Raney nickel, and copper chromite promoted by manganese. However, of these catalysts the most commonly encountered and most preferred is copper chromite.
The hydrogenation step is normally carried out at temperatures of from about 200° to about 350° C., although temperatures of about 300° C. are preferred. The hydrogenation is normally carried out at pressures of from about 100 to about 300 atmospheres, although pressures of from about 150 to about 250 atmospheres are preferred, in contrast to the 300 atmospheres and more used in prior commercial processes.
GENERAL DESCRIPTION OF THE DRAWING
The FIGURE is a graphic representation of the process of the present invention showing the reaction of carboxylic acids with alcohols to produce carboxylic acid esters, which are then hydrogenated to product alcohols.
DETAILED DESCRIPTION OF THE INVENTION
The sole FIGURE is a description of the process of the present invention wherein carboxylic acids are fed to a first stage (A) through line 1 together with product alcohols through line 2. In addition, the reactor is supplied with hydrogen and carbon monoxide through lines 3 and 4. Reactor (A) contains a finely divided support material to increase the surface available to the reaction which is carried out solely under conditions of temperature and pressure in the absence of a catalyst. Examples of such inert support materials which are used include glass beads, wash sand and the like.
In Reactor (A) organic acids are converted to organic acid esters and carbon dioxide, which exit the reactor through line 5. Carbon dioxide can be removed via line 6 and the organic acid esters proceed into reactor (B) which contains a hydrogenation catalyst of choice (preferably but not critically copper chromite in a fixed bed). The reactor is additionally supplied through lines 7 and 8 with additional hydrogen and carbon monoxide. The organic acid esters are hydrogenated to organic alcohols of the desired molecular weight range and exit the reactor through product line 9, from which slip stream line 2 is diverted for recycle to the reactor step (A).
The reaction which occurs in reactor (B) produces extremely high quality alcohols in high yield.
The reaction produces CO 2 , which can be disposed of with unreacted hydrogen feed gas. However, if hydrogen feed gas is recycled, unwanted CO 2 product is preferably continuously removed from the feed gas stream. CO 2 can be removed by means well known to those skilled in this art, such as by CO 2 scrubbers.
The instant invention is more concretely described with reference to the examples below wherein all parts and percentages are by weight unless otherwise specified. The examples are provided to illustrate the instant invention and not to limit it.
Examples 1 and 2 illustrate the first step of the process for the formation of carboxylic acid esters.
EXAMPLE 1
In a batch process a 2-liter stainless steel autoclave with stirrer was equipped with a gas bubbling device and a back-pressure regulator for gas flow control. The autoclave was charged with 350 grams (1.75 mole) of dodecanoic acid and 325.5 grams (1.75 mole) of dodecanol. The autoclave was evacuated and refilled with feed gas. The The autoclave was heated to 150° C. with agitation and an approximately 2 to 1 mixture of hydrogen to carbon monoxide was bubbled through the reaction mixture at a set pressure of 1000 psig. These conditions were maintained for 3 hours. The autoclave conditions were then reduced to ambient temperature and pressure. Pure carboxylic acid ester was thereafter ready for hydrogenation.
EXAMPLE 2
In a continuous process, a liquid feed consisting of 1:1 molar ratio mixture of dodecanoic acid and dodecanol is pumped into a glass bead packed stainless steel tubular reactor equipped with a backpressure regulator. The gaseous feed consisting of a 2:1 mixture of hydrogen and carbon monoxide is concurrently introduced into the reactor. The temperature and pressure of the reactor are maintained at 150° C. and 1000 psig respectively, and the liquid hourly space velocity of these conditions is maintained at 0.5. The pure carboxylic acid ester produced is ready for use as hydrogenation feed.
Catalytic hydrogenation of the carboxylic acid esters thus obtained is improved by using a hydrogen feed gas containing carbon monoxide and is illustrated in Example 3 for a batch process and in Example 4 for a continuous process.
EXAMPLE 3
A 2-liter stainless steel autoclave with stirrer is charged with 675.5 grams (1.75 mole) of dodecyl dodecanoate and 14.0 grams (2% by weight) of copper chromite hydrogenation catalyst. The autoclave is sealed, evacuated, and sparged with nitrogen at 100° C. A gaseous mixture of hydrogen and carbon monoxide in a ratio of 2:1 at a pressure of 500 psig is set on the autoclave while the temperature of the reaction is raised to 270° C. The feed gas pressure is then raised to 3000 psig and after 30 minutes at these conditions, the autoclave is cooled at ambient temperature and pressure is relieved. A typical example after several preparations with the same catalyst shows greater than 96% conversion of ester to alcohol.
EXAMPLE 4
A stainless steel tubular reactor is packed with a fixed bed of copper chromite hydrogenation catalyst and filled with carboxylic acid ester feed. Concurrent with the carboxylic acid ester liquid feed a gaseous mixture of hydrogen and carbon monoxide in the ratio of about 2:1 is bubbled through the reactor. The temperature and pressure of the reactor are gradually raised to 270° C. and 3000 psig over a period of 1 hour and maintained at these conditions for the balance of the run. The liquid hourly space velocity of the liquid feed is maintained at 0.5 under these conditions and a typical example of product shows 92 to 96% conversion of ester to alcohol.
It has been discovered that copper chromite catalysts when used for hydrogenation can be extended in life by maintaining the addition of carbon monoxide throughout the bed as is illustrated in Example 4.
When carried out continuously, the process of the instant invention is normally carried out at a liquid hourly space velocity (LHSV) of from about 0.1 to about 10. However, more commonly, LHSV of from about 0.3 to about 2 will be used and most preferred are LHSV of 0.3 to 1.0.
Although exemplified as separate stage reactors in the previous examples, the instant invention is especially situated to a 2-stage single reactor process as illustrated in Examples 5 and 6.
EXAMPLE 5
In a batch reaction a 2-liter stainless steel autoclave with stirrer is equipped with a gas bubbling device and a back-pressure regulator for gas flow control. The autoclave was charged with 350 grams (1.75 mole) of dodecanoic acid, 325.5 grams (1.75 mole) of dodecanol, and 14.0 gram (approximately 2% by weight) copper chromite hydrogenation catalyst. The autoclave is sealed, evacuated, and sparged with nitrogen at 100° C. Stirring is begun. A 2:1 mixture of hydrogen and carbon monoxide respectively is bubbled through the reaction mixture at a set pressure of 1000 psig. The temperature and pressure of the reaction are raised gradually to 270° C. and 3000 psig respectively over a 3 hour minute period. The conditions are maintained for 1 hour. The autoclave conditions are then reduced to ambient temperature and pressure. A typical sample after several preparations with the same catalyst will show that 92 to 96% conversion of acid to alcohol has occurred.
EXAMPLE 6
The first half of the stainless steel tubular reactor is packed with glass beads while the remainder of the reactor is packed with copper chromite hydrogenation catalyst. To initiate reaction the reactor is filled with a carboxylic acid ester liquid feed. To the same point of entry as the liquid feed a gaseous mixture of hydrogen and carbon monoxide in the ratio of 2:1 is bubbled through the reactor. The temperature of the first half of the reactor is raised gradually to 300° C. while the temperature of the second half of the reactor is raised gradually to 270° C. The entire reactor is maintained at a pressure of 3000 psig. The reaction conditions are reached gradually over a period of 1 hour. After reaction conditions are reached the liquid feed is changed to a 1 to 1.1 mixture of carboxylic acid and an alcohol respectively. The (LHSV) of the liquid feed is maintained at 0.5 under these conditions. A typical sample of product will show a 92 to 96% conversion of acid to alcohol.
Thus it is apparent that the instant invention provides a simple mild reaction condition process for the conversion of organic acids to alcohols while maintaining molecular weight control. The reaction likewise is a simple easily carried out process which produces alcohols of high purity.
While certain embodiments and details have been shown for the purpose of illustrating this invention, it will be apparent to those skilled in this art that various changes and modifications may be made herein without departing from the spirit or scope of the invention. | An improved process is provided for the production of alcohols from carboxylic acids using the reaction of carboxylic acids with alcohols in the presence of hydrogen and carbon monoxide to form esters which are subsequently hydrogenated over a suitable hydrogenation catalyst. The invention is useful because the temperature and pressure conditions are reduced from current commercial processes while hydrogenation catalyst activity and lifetime are promoted by the removal of catalyst poisons such as water. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/710,317, filed Aug. 22, 2005.
FIELD OF THE INVENTION
[0002] The present invention relates to an all-metal hinge motion check friction device for incorporating into a hinge assembly for holding a hinge open at a selected position. In particular, the present invention is useful for incorporating into vehicle door hinges, particularly when the vehicle is being painted during manufacturing, so that the door remains in a desirable fixed position to facilitate painting operations.
BACKGROUND OF THE INVENTION
[0003] Hinges are widely used to connect two or more members, allowing them to rotate relative to one another. Examples of the use of hinges include connecting lids to containers and doors to frames. They are often designed to rotate relatively freely between preset stopping points, such as fully open or fully closed positions. However, in many instances it would be desirable to be able to reversibly position the members at a selected position relative to one another in such a way that they are both held in position and do not further rotate relative to each other. To accomplish this it would be beneficial to incorporate a hinge design such that the members connected by the hinge can first withstand the relatively low outside forces, such as the sometimes jerky movement of a conveyor line moving along an unpainted car body with its doors open by as much as 70 degrees in the assembly plant. Further with such a hinge the members retain their positions relative to each other when subjected to this movement, but can be further moved to other selected positions by the use of a force that is greater than that experienced by the members during , say, the above-mentioned assembly line movement acting on the open doors. By “reversibly position” is meant that the members can be repeatedly moved relative to one another from the position in which they were initially placed, and maintained in that subsequent position regardless of movement of the body to which the members are attached.
[0004] The use of such a hinge device would be particularly useful in vehicle doors, and in particular during the vehicle manufacturing process. During manufacturing, vehicles such as automobiles are often painted in a multi-step process on assembly lines. During the painting process, it is often necessary to open, close, and otherwise adjust the positions of doors connected to the bodies of vehicles by hinges relative to the bodies, often in an automated fashion by robots.
[0005] A variety of devices and techniques incorporating metal have been used in the past to position hinged members. Metal is an attractive material because it can withstand the forces encountered in moving hinged members along assembly lines. For example, previous attempts using metal assembly include positioning doors to be placed and held in desired positions using wire forms or metal brackets. However in such instances these supports must be individually installed, adjusted, and removed, which requires intervention by a worker and thus adds complexity to the painting process. Furthermore, after a few cycles in the painting process, it is often necessary to clean the supports, making this technique still more complex and labor-intensive.
[0006] It is known in the automotive construction process to use designs which incorporate tightly fitting plastic collar devices around a vehicle door hinge pin, and these collar devices are intended to provide resistance to door rotation. For example, such plastic collar devices have been observed on current production Ford F-150 pickup trucks. However, during the painting process, the vehicles can go through several heating and cooling steps during which the maximum temperature can reach or exceed 120° C., which can cause the plastic collar to lose its grip on the hinge pin as the plastic is annealed and expands and contracts during the heating and cooling cycles. This can lead to inconsistent and unreliable operation of the device as it will often fail to hold the door firmly in a desired position. All-metal designs are not necessarily limited in this manner, and therefore a metal device that can withstand several heating and cooling cycles without losing its grip on a hinge pin would be desirable.
[0007] It is an object of the present invention to obtain an all-metal device capable of holding two members connected by one or more hinges in a selected position between or including fully open (meaning the hinge surfaces maintain the members as far apart as possible) or fully closed (meaning that the hinge surfaces maintain the members in closest proximity to one another) that did not require the use of supports that must be manually removed and reinstalled each time the position of the members needed to be changed. It is a further object of the present invention to provide an all-metal device that does not incorporate plastic collars as mentioned above, instead providing a simple design which can withstand the rigors of automated assembly line processes, including paint baking or other high temperature exposure without significant degradation of its original frictional resistance to movement. A feature of the present invention is in one embodiment the use of such a device in a vehicle door hinge assembly. An advantage of the present invention is that such a device can maintain its predetermined position while experiencing the forces imparted on the vehicle body and the resultant inertial forces on an open door by the jerky motion of starting and stopping of many conveyer operations by not preventing the vehicle door from moving significantly from its set position, even after being exposed to several consecutive high temperature paint baking cycles. These and other objects, features and advantages of the invention will become better understood upon having reference to the detailed description herein.
SUMMARY OF THE INVENTION
[0008] There is disclosed and claimed herein a hinge motion check friction device for holding a hinge connecting at least two members at an arbitrary position with a hinge pin, comprising a metal sleeve containing an opening into which is inserted the hinge pin and frictionally secures the hinge members in the position selected, and an integral metal tab projecting laterally from said metal sleeve which maintains the hinge members in the position selected.
[0009] Alternatively there is disclosed and claimed herein an improvement for an all-metal device for frictionally connecting hinge members at a selected position, comprising a metal sleeve containing an opening into which is inserted the hinge pin. The improvement comprises said metal sleeve frictionally securing the hinge members in the position selected, and a metal tab projecting laterally from said metal sleeve which maintains the hinge members in the position selected.
[0010] The present invention will become better understood upon having reference to the drawings herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIGS. 1A and B are side and top views respectively, of a design of a metal friction device according to the invention;
[0012] FIGS. 2A and B are side and top views respectively, of an alternative design of a metal friction device according to the invention; and
[0013] FIGS. 3A and B are side and top views respectively, of a still further alternative design of a metal friction device according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The friction device of the present invention comprises a metal sleeve such as a metal split tubular sleeve and through which a hinge pin connecting two or more hinge members is inserted, such that once positioned within the assembly, the metal sleeve is rotationally fixed to the hinge pin and cannot rotate within the assembly. The hinge pin is interlocked with one of the hinge members. The metal sleeve comprises a metal tab projecting laterally from the metal sleeve and that interlocks one or more hinge members that are different from the hinge member to which the hinge pin is interlocked, thus impeding relative motion of the hinge members. As used herein, by the term “interlocked”, it is meant that whenever a first part is in intimate contact with a second, separate part, any force applied to the first part to create movement in a particular direction causes simultaneously an equal movement of the second part in the same general direction.
[0015] Having reference to FIGS. 1A and B, there is shown generally at 10 the friction device of the present invention, comprising a metal sleeve 12 and a metal tab 14 projecting laterally therefrom. The metal sleeve 12 is provided with opening 16 through which the hinge pin extends. The metal tab 14 can be broken off the slotted cylindrical body of the metal sleeve 12 by placing the slotted end of a special tool over the metal tab 14 and twisting the tool to shear off the metal tab 14 at the narrow transition area 18 between the metal tab 14 and the cylindrical friction portion of this device. In the embodiment depicted in these figures, the metal tab 14 comprises two leading edge portions 20 and a recessed area 22 therebetween.
[0016] In use a vehicle door hinge pin (not shown) may be inserted through the center of the friction device 10 . The hinge pin fastens a door-side hinge member (which is secured to a door by fastening means not shown) to a body-side hinge member (which is secured to a body by fastening means also not shown). The configuration of the metal sleeve 12 and opening 16 is sized to accommodate the insertion of the hinge pin. The hinge pin may include a tapered end to facilitate this insertion. When the hinge pin is inserted through the friction device 10 , the metal sleeve 12 expands in diameter, creating significant friction between friction device 10 and the hinge pin, such that the friction device 10 does not freely rotate around the hinge pin.
[0017] Having reference to FIGS. 2A and B, there is shown again generally at 10 an alternative embodiment of the device as depicted in FIGS. 1A and B, but featuring only one leading edge portion 20 in combination with a recessed area 22 . In the designs of all such devices shown in the figures disclosed herein, and when incorporated into an assembly as described above, the hinge pin inserted through friction device 10 and the door-side hinge member and the body-side hinge member. One or more assembled hinges may be used to attach a vehicle door to the body of a vehicle, preferably an automobile. Preferably, the door-side member will be attached to the door and the body-side hinge member will be attached to the body. Metal tab 14 is designed such that it contacts either door-side hinge member or body-side hinge member 22 , and serves as an interlock to couple the frictional resistance to rotation in either direction between the friction device 10 and hinge pin. In so-doing, the metal tab 14 transfers a rotational force from the door hinge, forcing the friction device 10 to rotate around the hinge pin to follow the door and overcoming the friction between the friction device 10 and hinge pin in the process. In one embodiment of the present invention, contact between metal tab 14 and the hinge member may be through a hole in the hinge member into which the metal tab 14 is inserted.
[0018] The hinge pin is interlocked to one of the hinge members. When metal tab 14 is designed such that it contacts the door-side hinge member, the hinge pin is interlocked with the body-side hinge member. When metal tab 14 is designed such that it contacts the body-side hinge member, the hinge pin is interlocked with the door-side hinge member. The hinge pin may be interlocked with the appropriate hinge member by serrations, scoring, grooves, or other details present in on the hinge pin that mate with complimentary serrations, scoring, groove, or other details on the hinge member when the hinge pin is inserted into the hinge member. Any other suitable method of interlocking the hinge pin to the hinge member may also be employed. When sufficient force is applied to the hinge, the door-side hinge member will rotate relative to the body-side hinge member. However, the frictional resistance is great enough that absent such force, the door-side hinge member and body-side hinge member will maintain their relative positions, particularly when used to mount a vehicle door to a vehicle that is conveyed along a painting line. As the vehicle moves along the painting line, the position of the door may be adjusted as needed by the application of force sufficient to overcome the frictional resistance between friction device 10 and hinge pin. However, the frictional resistance will be sufficient to keep the door in place when subjected to normal motion along the line, which can include jolts from starting and stopping the line, even after subjected to repeated heating and cooling cycles.
[0019] FIGS. 3A and B provide yet another alternative design for the metal friction device of the invention, again as shown generally at 10 . This design features similar components as in the designs of the earlier figures, with the cylindrical friction body of the device gripping a hinge pin tightly, thereby providing essential friction to hold a door in the position in which it is preferentially placed. In this case the metal tab 14 includes bifurcated leading edges 20 which engage the edge of the hinge until one or both tabs are broken off by twisting the tab end beyond the v-notch 21 provided therealong. The v-notch 21 allows breaking off one or both tabs from cynlidrical friction body by twisting the tab 14 beyond the v-notch 21 . Breaking of a tab 14 disconnects the friction device from the hinge half. As can be seen in FIG. 3B , the metal tabs 14 are separated by space so tha the edge of the hinge can bit between tabs and the force the friction device to rotate on the hinge pin.
[0020] Metal tab 14 is designed such that it may be conveniently removed from contacting a hinge member when it is no longer desirable to hold the hinge members in a selected position, such as when free motion between the members is desired. As shown in each of the Figures, the metal tab 14 is preferably connected to metal sleeve 12 by a narrow transition area 18 . This allows metal tab 14 to be conveniently broken or cut off when, for example, the painting/assembly operation of a vehicle is complete. It is readily appreciated that other designs of the metal tab 14 can be incorporated to allow convenient breakage. For example, the surface thereof may be pre-scored sufficiently prepare it for breakage. Alternatively the metal tab 14 may be shaped as to introduce other weak points along the surface thereof, so that when subjected to torsional or flexural forces the metal will reliably and predictably break at a designated location therealong. Moreover and as introduced earlier the metal tab 14 can be broken off, by cutting with a suitable tool, and the like. When the metal tab 14 is broken off, the friction device is no longer interlocked with door-side hinge 20 , allowing the door to move freely about its hinges thereafter, as would be preferred for normal use of the vehicle after assembly. The remainder of the device may remain present as part of hinge assembly during the life of the vehicle. Moreover because the remainder of the device is frictionally engaged with the hinge pin it is secured within the vehicle and does not contribute to the noise within the occupant compartment. Alternatively, metal tab 14 may be bent such that it no longer contacts hinge members.
[0021] The metal tab 14 will preferably be formed as an integral part of metal sleeve 12 . Alternatively, the metal tab 14 may be made from one or more pieces of metal that have been designed to fit together as an integral metal part. The metal tab 14 may also be snap-fit or press-fitted or welded to the metal sleeve 12 . In certain variants of this embodiment, the metal tab 14 may be removed without breakage and could be reusable. In addition, the metal tab 14 may extend along the length of the metal sleeve 12 or at one or more portions thereof, so long as it contacts the door side hinge member or the body side hinge member as appropriate. Such a sleeve design is sufficiently rigid for structural integrity while at the same time sufficiently flexible to accommodate the hinge pin.
[0022] Metal sleeve 14 will preferably be made from steel, and more preferably steel that has been treated to give it a spring-like quality.
[0023] The degree of friction, and hence resistance to rotation, between friction device 10 and the hinge pin can be adjusted by a variety of means, including varying the difference between the inner diameter of metal sleeve 12 and the diameter of the hinge pin; by increasing the wall thickness of metal sleeve 12 ; by altering the length of metal sleeve 12 ; by altering the heat and/or surface treatment of metal sleeve 12 ; and/or by changing the alloy of the metal, preferably steel, used to make the metal sleeve 12 . Other approaches include changing the characteristics of the hinge pin, such as surface hardness, type of metal, and/or applying a special plating or coating. Therefore one of sufficient skill in the art to which the invention pertains can with little or no advance experimentation design into the friction device 10 the appropriate degree of friction to suit a specific purpose.
[0024] The force required to rotate a hinge pin inserted into device 10 of the present invention is preferably about 5 to about 60 N-m, or more preferably about 15 to about 35 N-m. when deployed for purposes of holding automobile doors in a selected position during the vehicle manufacturing process. For other purposes the preferred force will vary according to the application selected. | All-metal hinge motion check friction device for incorporating into a hinge assembly useful for holding a hinge open at a selected position. The hinge motion check friction device is useful for incorporating into vehicle door hinges, particularly when the vehicle is being painting during manufacturing. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to stock monitoring techniques, and more particularly to improving the accuracy and functionalities of electronic stock monitoring.
[0003] 2. Discussion of the Related Art
[0004] In prior art systems, the amount of stock retrieved or removed from storage has been determined from changes in weight measurements for a bin or container for parts, knowing the unit weight of the part.
[0005] GB2299074A discloses a monitoring system for a storage system, comprising a plurality of bins or other storage means 10 containing stock, comprises sensing means 12 associated with the storage means 10 to monitor the contents of the storage means 10 and periodically to generate signals indicative of the contents of the storage means 10 and processing means 13 adapted to receive the signals of the contents of the storage means 10 and to compare the measured contents of each storage means 10 with a respective predetermined level of contents and, if the measured contents has fallen below the predetermined level of contents, to generate a signal to instigate an order to replenish the stock in the respective storage means 10.
[0006] However, a problem with such systems is that in order to measure stock movement from bins, weight sensors are read continuously; as weight sensors are subject to drift in their output readings, there is the significant possibility of miscounting stock quantities, especially in cases where the unit weight of the stock items is small.
SUMMARY OF THE INVENTION
[0007] This invention concerns systems and methods for providing monitoring of quantities of stock in an accurate and preferably secure manner, in storage environments where hand-portable stock items can be stored and accessed by a user or, more typically, a multitude of different users or employees. Such storage environments are typically found at manufacturing and other sites.
[0008] According to one aspect of the invention there is provided a method carried out in a stock monitoring system, the stock monitoring system comprising: a housing, one or more doors disposed in or on the housing, a sensor for sensing the condition of the door(s) and providing a door closed signal indicative of the door(s) having been closed by a user, one or more containers for stock items, located within the housing, the or each container having associated therewith a weight sensor for providing a weight signal indicative of the current weight of the container, and control circuitry, coupled for communication with the weight sensor(s); wherein the method comprises (a) receiving a door closed signal; (b) receiving one or more weight signals; (c) determining, for the or each container, the number of stock items removed from the container(s) by the user, from the weight signal(s) occurring during a predetermined sensing period, the predetermined sensing period being dependent upon the door closed signal.
[0009] Preferably, the predetermined sensing period comprises a first predetermined time period after the door closed signal. Preferably, the first predetermined time period is about 30 to about 90 seconds, for example about 60 seconds.
[0010] Preferably, (c) comprises, for the or each container, determining a current average weight of the container by averaging the weight signals over the predetermined sensing period; determining the weight difference for the container, the weight difference being the difference between the current average weight and the previously determined average weight; and dividing the weight difference by a weight unit stored in memory in association with an identifier for the container, thereby obtaining the number of stock items removed from the container by the user.
[0011] Preferably, the stock monitoring system further comprises a user ID sensor, adapted to be activated by a user and the method further comprises: (d) obtaining a user ID from the user ID sensor upon activation by a user; (e) determining if the user ID obtained is valid. The user ID sensor may be a swipe card reader, and (d) comprises extracting a user ID from a swipe card upon swiping by a user. Alternatively, the user ID sensor is a Dallas key sensor, and (d) comprises extracting a user ID from a Dallas key upon activation of the Dallas key sensor by a user using his Dallas key.
[0012] Preferably, the stock monitoring system further comprises one or more electrically controlled locks associated with the door(s), the lock(s) being electrically controllable such that the door(s) are in either a locked or releasable condition, the control circuitry being coupled for communication with the locks. The method may further comprise: (f) if door open conditions are met, priming the doors for opening, whereby the door(s) are in said releasable condition. In the alternative, (f) comprises: (f′) if door open conditions are met, causing the door(s) to open, for example, to rotate to an open position. The door open conditions may comprise: (A) the obtained user ID is a valid ID, (B) the user ID obtained is different from the previously obtained user ID; and (C) the predetermined sensing period has elapsed; wherein the predetermined sensing period comprises a second predetermined time period after the door closed signal, different from the first predetermined time period. Alternatively, the door open conditions comprise: (D) the obtained user ID is a valid ID, (E) the user ID obtained is the same as the previously obtained user ID; and (F) the predetermined sensing period has not elapsed; wherein the predetermined sensing period comprises a second predetermined time period after the door closed signal, different from the first predetermined time period. Preferably, the second predetermined time period is about 10 to about 30 seconds, for example about 15 seconds.
[0013] Preferably, the method further comprises: (g) if the door(s) have not been opened by the user with a third predetermined time period after the doors have been primed for opening, activating the lock(s) so that the door(s) are in a locked condition. Preferably, the third predetermined time period is about 20 seconds to about 40 seconds, and is for example 30 seconds.
[0014] The doors comprise exterior doors. Each door may provide user access to a single container or to multiple containers.
[0015] Alternatively, the housing includes one or more drawers; each drawer having one or more compartments, and the doors comprise or include the lid(s) of the compartment(s).
[0016] In one embodiment, a single weight sensor is associated with a plurality of bins and/or compartments and provides a weight signal indicative of the combined weight of the plurality of bins or compartments.
[0017] The method may further comprise (h) obtaining, periodically or in response to user input, for one or more of the containers, an absolute weight reading from the weight sensor associated with the container, thereby obtaining the number of stock items in the container.
[0018] The method step (d) may include: determining whether the user ID sensed by the user ID sensor is a user ID of a first type, for users removing stock items, or a user ID of a second type, for users restocking the housing with stock items. In this embodiment, the method preferably further includes (i) if it is determined the obtained user ID is of the second type, determining, for the or each container, after a door closed signal is received, the number of stock items added thereto by the user performing restocking; and k) transmitting the number(s) of stock items to a server; and (k) storing number(s) of stock items in a file on the server.
[0019] Preferably, the stock control system further includes a display unit, the display unit including a indicator in a first colour, e.g. red, an indicator in a second colour, e.g. amber, and one or more indicators, including a main indicator, in a third colour, e.g. green, wherein the method preferably includes (l) illuminating the main indicator in the system ready state, in which a user ID sensing is awaited; and/or (m) if it is determined that an obtained user ID is not valid, illuminating the indicator in the second colour for a period, e.g. about 4 seconds, prior to illuminating the main indicator; and/or (n) if it is determined that an obtained user ID is valid, illuminating said one or more indicators in the third colour, and/or (o) in response to a door closed signal, switching off said one or more indicators in the third colour other than the main indicator, and illuminating the indicator in the second colour, and/or (p) following a door closed signal, and in response to the weight sensor reading being successfully transmitted, switching off said indicator in the second colour.
[0020] According to another aspect of the invention there is provided a stock monitoring system when suitably programmed for carrying out the method of any of claims 1 to 4 of the appended claims, the stock monitoring system comprising: a housing, one or more doors disposed in or on the housing, a sensor for sensing the condition of the door(s) and providing a door closed signal indicative of the door(s) having been closed by a user; one or more containers for stock items, located within the housing, the or each container having associated therewith a weight sensor for providing a weight signal indicative of the current weight of the container, and control circuitry, coupled for communication with the weight sensor(s).
[0021] According to another aspect of the invention there is provided a stock monitoring system when suitably programmed for carrying out the method of any of claims 5 , 6 or 7 of the appended claims, the stock monitoring system comprising: a housing, one or more doors disposed in or on the housing, a sensor for sensing the condition of the door(s) and providing a door closed signal indicative of the door(s) having been closed by a user; one or more containers for stock items, located within the housing, the or each container having associated therewith a weight sensor for providing a weight signal indicative of the current weight of the container, control circuitry, coupled for communication with the weight sensor(s), and a user ID sensor, adapted to be activated by a user.
[0022] According to another aspect of the invention there is provided a stock monitoring system when suitably programmed for carrying out the method of any of claims 8 to 22 of the appended claims, the stock monitoring system comprising: a housing, one or more doors disposed in or on the housing, a sensor for sensing the condition of the door(s) and providing a door closed signal indicative of the door(s) having been closed by a user; one or more containers for stock items, located within the housing, the or each container having associated therewith a weight sensor for providing a weight signal indicative of the current weight of the container, control circuitry, coupled for communication with the weight sensor(s), a user ID sensor, adapted to be activated by a user, and one or more electrically controlled locks associated with the door(s), the lock(s) being electrically controllable such that the door(s) are in either a locked or releasable condition, the control circuitry being coupled for communication with the locks.
[0023] According to another aspect of the invention there is provided a stock monitoring system, comprising: a housing, one or more doors disposed in or on the housing, a sensor for sensing the condition of the door(s) and providing a door closed signal indicative of the door(s) having been closed by a user; one or more containers for stock items, located within the housing, the or each container having associated therewith a weight sensor for providing a weight signal indicative of the current weight of the container, control circuitry, coupled for communication with the weight sensor(s); wherein the control circuitry is operable for (a) receiving a door closed signal; (b) receiving one or more weight signals; (c) determining, for the or each container, the number of stock items removed from the container(s) by the user, from the weight signal(s) occurring during a predetermined sensing period, the predetermined sensing period being dependent upon the door closed signal.
[0024] Preferably, the predetermined sensing period comprises a first predetermined time period after the door closed signal. Preferably, the first predetermined time period is about 30 to about 90 seconds, for example about 60 seconds.
[0025] Preferably, (c) comprises for the or each container, determining a current average weight of the container by averaging the weight signals over the predetermined sensing period; determining the weight difference for the container, the weight difference being the difference between the current average weight and the previously determined average weight; dividing the weight difference by a weight unit stored in memory in association with an identifier for the container, thereby obtaining the number of stock items removed from the container by the user.
[0026] Preferably, the stock monitoring system further comprises a user ID sensor, adapted to be activated by a user and, wherein the control circuitry is operable for: (d) obtaining a user ID from the user ID sensor upon activation by a user; (e) determining if the user ID obtained is valid. The user ID sensor may be a swipe card reader, and (d) comprises extracting a user ID from a swipe card upon swiping by a user. Alternatively, the user ID sensor is a Dallas key sensor, and (d) comprises extracting a user ID from a Dallas key upon activation of the Dallas key sensor by a user using his Dallas key.
[0027] Preferably, the stock monitoring system further comprises one or more electrically controlled locks associated with the door(s), the lock(s) being electrically controllable such that the door(s) are in either a locked or releasable condition, the control circuitry being coupled for communication with the locks. The control circuitry may be operable for: (f) if door open conditions are met, priming the doors for opening, whereby the door(s) are in said releasable condition. Alternatively, the control circuitry may be operable for (f′) if door open conditions are met, causing the door(s) to open, for example, to rotate to an open position. The door open conditions may comprise: (A) the obtained user ID is a valid ID, (B) the user ID obtained is different from the previously obtained user ID; and (C) the predetermined sensing period has elapsed; wherein the predetermined sensing period comprises a second predetermined time period after the door closed signal, different from the first predetermined time period. Alternatively, the door open conditions comprise: (D) the obtained user ID is a valid ID, (E) the user ID obtained is the same as the previously obtained user ID; and (F) the predetermined sensing period has not elapsed; wherein the predetermined sensing period comprises a second predetermined time period after the door closed signal, different from the first predetermined time period. Preferably, the second predetermined time period is about 10 to about 30 seconds, for example about 15 seconds.
[0028] The control circuitry may be operable for: (g) if the door(s) have not been opened by the user with a third predetermined time period after the doors have been primed for opening, activating the lock(s) so that the door(s) are in a locked condition. Preferably, the third predetermined time period is about 20 seconds to about 40 seconds, and is for example 30 seconds.
[0029] The doors comprise exterior doors. Each door may provides user access to a single container or to multiple containers.
[0030] Alternatively, the housing includes one or more drawers; each drawer having one or more compartments, and the doors comprise or include the lid(s) of the compartment(s).
[0031] In one embodiment, a single weight sensor is associated with a plurality of bins and/or compartments and provides a weight signal indicative of the combined weight of the plurality of bins or compartments.
[0032] The control circuitry may be operable for: (h) obtaining, periodically or in response to user input, for one or more of the containers, an absolute weight reading from the weight sensor associated with the container, thereby obtaining the number of stock items in the container.
[0033] The control circuitry may be operable such that (d) includes: determining whether the user ID sensed by the user ID sensor is a user ID of a first type, for users removing stock items, or a user ID of a second type, for users restocking the housing with stock items. Preferably, the control circuitry is operable for: (i) if it is determined the obtained user ID is of the second type, determining, for the or each container, after a door closed signal is received, the number of stock items added thereto by the user performing restocking; and (j) transmitting the number(s) of stock items to a server; and (k) storing number(s) of stock items in a file on the server.
[0034] Preferably, the stock control system further includes a display unit, the display unit including a indicator in a first colour, e.g. red, an indicator in a second colour, e.g. amber, and one or more indicators, including a main indicator, in a third colour, e.g. green. Preferably, control circuitry is operable for: (l) illuminating the main indicator in the system ready state, in which a user ID sensing is awaited; and/or (m) if it is determined that an obtained user ID is not valid, illuminating the indicator in the second colour for a period, e.g. about 4 seconds, prior to illuminating the main indicator; and/or (n) if it is determined that an obtained user ID is valid, illuminating said one or more indicators in the third colour, and/or (o) in response to a door closed signal, switching off said one or more indicators in the third colour other than the main indicator, and illuminating the indicator in the second colour, and/or (p) following a door closed signal, and in response to the weight sensor reading being successfully transmitted, switching off said indicator in the second colour.
[0035] According to another aspect of the invention there is provided a recordable, rewritable or recorded medium having recorded or stored thereon machine readable data defining or transformable into instructions for execution by processing circuitry and corresponding to at least the steps of the methods set out in any of claims 1 to 23 of the appended claims.
[0036] According to another aspect of the invention there is provided a server computer incorporating a communications device and a memory device and being adapted for transmission on demand or otherwise of data defining or transformable into instructions for execution by processing circuitry and corresponding to at least the steps of any of claims 1 to 23 of the appended claims.
[0037] Using techniques according to the invention, rather than continuously sensing weight measurements from weight sensors or load cells, the measurements are taken only for a relatively short period after the doors of the housing have been closed by a user (typically after removal of stock by the user). Weight measurements are averaged over a period of one minute, or at least over a period of at least 15 seconds or so. In this way, measurements are more accurate and effects of weight measurement drift are reduced or eliminated. So the accuracy in counting quantities of stock removed is increased, in some cases exceeding 99% accuracy.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] Embodiments of the invention will now be described in detail, by way of example, with reference to the accompanying drawings, in which:
[0039] FIG. 1 shows a housing or cabinet employed in the stock monitoring system according to a first embodiment of the invention;
[0040] FIGS. 2A and 2B illustrate the effect of weight sensor drift;
[0041] FIG. 3 is a schematic block diagram showing the main electrical components in the stock monitoring system according to the first embodiment; and
[0042] FIGS. 4A and 4B are a flow chart showing the main processing steps and operations in implementing stock monitoring according to the first embodiment;
[0043] FIG. 5 is a schematic block diagram showing the main electrical components in the stock monitoring system according to a second embodiment of the invention;
[0044] FIGS. 6A and 6B are a flow chart showing the main processing steps and operations in implementing stock monitoring according to the second embodiment;
[0045] FIGS. 7A-7C shows a housing or cabinet employed in the stock monitoring system according to a third embodiment of the invention, employing compartmentalised drawers, with (a) a lateral front view of the drawers, and (b) plan and (c) side views of a drawer;
[0046] FIG. 8 is a schematic block diagram showing the main electrical components in the stock monitoring system according to the third embodiment; and
[0047] FIGS. 9A-9C are a flow chart showing the main processing steps and operations in implementing stock monitoring according to the third embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0048] In the following, like numerals will be used to denote like elements. Certain techniques disclosed in GB2299074A may be employed in implementing the present invention, as appropriate, except as described hereinafter. Stock items may be, for example, automotive components, electrical components or fasteners and PPE and MRO consumables. In general every item contained in each particular bin 10 will be identical, but this is not essential. Equally, “stock items” may refer to consumable products or parts, re-usable products or parts, finished products or articles, tools, items of clothing, or any other item that is stored in pluralities and may be used or re-used by one or more persons.
[0049] FIG. 1 shows a housing or cabinet employed in the stock monitoring system according to a first embodiment of the invention, (a) in front view and (b) in side view. The cabinet 100 comprises a main body 102 and a pair of doors 104 having transparent (e.g. glass, Perspex) panels 105 . Here, two doors are illustrated, but 1, 3 or more may be used. The doors 104 and main body 102 are suitably made of steel, but any other suitably strong and rigid material may be used.
[0050] A plurality of shelves 106 are provided within the cabinet 100 , on each of which are mounted a plurality of storage bins 108 (here, for simplicity, only one shelf 106 is shown supporting bins). Each bin 108 sits on top of a weight sensor, suitably comprising a load cell 110 as is known to persons skilled in the art, each load cell 110 providing an anolog signal indicating the weight of the bin 108 it is supporting. (in alternative embodiments, there may be one load cell 110 for two or more bins 108 ). Each bin 108 stores stock items 112 . Stock may be, for example, automotive components, electrical components or fasteners. In general every item contained in each particular bin 108 will be identical.
[0051] Provided at the top right corner of the cabinet 100 is a swipe card reader 114 which is able to read swipe cards belonging to users (e.g. factory employees) and, depending on the ID extracted from the swipe card, cause the doors to be released for opening by the user, or not. Although, in this embodiment, a swipe card reader is used, it will be appreciated that other means of obtaining the user ID may be used, including, for example, IR or short range radio based portable devices, barcode readers, RFID systems, biometric (e.g. fingerprint, retina scan) devices, and so forth. Dalls keys may also be used.
[0052] FIG. 2 illustrates the effect of weight sensor drift. In FIGS. 2( a ) and ( b ), the weight signal output by the load cell 110 against time t is indicated by traces T and T′ respectively, the levels L 1 to L 4 indicate the transition between different numbers (quantities) being recorded as being within the respective bin 108 .
[0053] As shown, although highly exaggerated, the traces T, T′ are not flat (constant), but drift. In the case of FIG. 2( a ) the stock items 112 are of a higher unit weight than those for FIG. 2( b ). Thus, for FIG. 2( a ), the drift does not cause a false reading, but in FIG. 2( b ), the drift is such as to pass through threshold level L 3 , meaning that the weight signal sent by the load cell corresponds to a quantity in the bin that is false, i.e. is one less than the actual value.
[0054] For the cabinet-based system with doors ( FIG. 1 ), there are two variants of the system. The first variant, shown in FIGS. 3 and 4 , has a separate multiplexor 302 , Vlinx Box 310 and controller 316 . The second variant, shown in FIGS. 5 and 6 , is essentially the same as the first, except that it has one controller ( 516 ) replacing multiplexor 302 , Vlinx Box 310 and controller 316 . In a first variant, the locks to the doors in are primed for release and have to be pushed to be released. In a second variant, the locks to the doors in are released automatically when the card is swiped.
[0055] FIG. 3 is a schematic block diagram showing the main electrical components in the stock monitoring system according to a first embodiment of the invention. Each load cell 110 (only one of which is shown) is coupled to a multiplexer 302 . The load cells 110 send analog weight readings to the multiplexer 302 and receive LED status signals from the multiplexer 302 . As indicated by the key 304 , each load cell 110 incorporates or is coupled to and associated with, a simple status indicator (e.g. using LEDs), including amber left LED 306 and a right red LED 308 . The status currently being indicated by the LEDs is as set out in the diagram (key 304 ).
[0056] Multiplexer 302 averages weight readings received from the load cell(s) 110 and converts the analog average reading to a digital reading. The multiplexer 302 sends load cell digital readings and multiplexer status signals to a serial-to-Ethernet conversion unit 310 , and receives therefrom, when appropriate, calibration requests (e.g. when an absolute weight measurement of one or more of the bins 108 is performed). The serial-to-Ethernet conversion unit 310 suitably comprises a Vlinx™ Ethernet serial server available from B&B Electronics Ltd, Co. Galway, Ireland (see, for example (a) http://www.bb-elec.com/product_family.asp?familyid=2 and (b) http://www.bb-elec.com/bb-elec/literature/ESP904-4105ds.pdf). The serial-to-Ethernet 310 connects, configures, and communicates with serial devices over Ethernet using a single IP address. The unit uses DB9 male serial connectors and supports RS-232, RS-422 and RS-485. The serial-to-Ethernet conversion unit 310 transmits load cell digital readings and multiplexer status signals to a network switch 312 and receives therefrom online/offline request signals.
[0057] The network switch 312 is of the type well known to persons skilled in the art for implementing Ethernet based LAN or WAN systems, enabling computers to communicate using TCP/IP, Ethernet and other protocols.
[0058] Referring briefly to FIG. 1 , the doors 104 can be locked using electrically controlled locks (not shown in FIG. 1 ). These locks are of the type known in the art (e.g. part no. INV02, available from Inventor-e Ltd). The locks are designated 314 in FIG. 3 . In this embodiment, these are activated (locking doors 104 ( FIG. 1 )) after both doors are shut.
[0059] The locks 314 send lock status signals to a door controller 316 . Also, the locks 314 receive control signals from the door controller 316 as follows:
“Set door lock” “Timeout” (after set period of time to relock doors), and “Prime doors for release”.
The door controller 316 may be any suitable microprocessor-based controller known in the art.
[0063] The door controller 316 sends lock status signals to the network switch 312 and receives therefrom, when appropriate, reboot messages.
[0000] The network switch 312 is further coupled to a rack PC 318 . This is a computer with standard (PC) architecture, with mountings, components/interfaces and specifications for use in industrial environments. Rack PC 318 suitably
stores a database (of user IDs) for controlling door access processes load cell readings and converts them to quantities of parts/stock items stores Part IDs, part unit weights, user IDs and location IDs.
[0067] Optionally, the rack PC 318 is coupled to a web server 329 and sends stored and derived data thereto. In turn, the web server 320 is able to supply on demand (e.g. over internet and subject to password access) reports on data obtained from the rack PC, enabling a remote user (e.g. supplier) to view reports and download (e.g. into a suitable software package such as MS Excel).
[0068] The link between the multiplexer 302 and the rack PC 318 may be a wired link, using suitable network hardware and protocols. Alternatively, a suitable wireless link may be used, e.g. GPRS.
[0069] Referring to the load cells 110 in FIG. 3 , although the display has been indicated as a simple LED display, in an alternative embodiment the load cells incorporate or are associated with a display (e.g. LCD) that displays the current total quantity of items in the respective bin 108 based on data received from the rack PC 318 .
[0070] FIG. 4 is a flow chart showing the main processing steps and operations in implementing stock monitoring according to the first embodiment of the invention. Commencing at 402 , here the stock monitoring system is in a “system ready” state, ready for a user to attempt to access the cabinet 100 . In addition (see bottom left of FIG. 4 ), mounted in or on the cabinet 100 , coupled to the door controller 316 and visible to the user is a user display incorporating a number of LEDs. This includes upper red LED ( 1 ), a middle amber LED ( 2 ) and three green lower LEDS ( 3 ), ( 4 ), ( 5 ). In the “system ready” state, green LED ( 3 ) is illuminated.
[0071] At 404 , a user swipes his swipe card through the card reader ( 114 in FIG. 1 ). Then, the extracted card (user) ID is sent to the rack PC 318 , and a card acceptance/rejection message returned (depending on whether the user ID is an authorised/valid ID in the database stored on rack PC 318 ).
[0072] The two possibilities are indicated at 406 . As indicated at 408 , if the card (ID) is not valid, then doors 104 are not primed for opening, the rack PC 318 send a message to the door controller 316 to display a predetermined indication. At 408 ( FIG. 4 ), an LED status message is sent to the door controller to illuminate LED ( 2 ) for 4 seconds, prior to returning to the “system ready” state, with only LED ( 3 ) illuminated.
[0073] If the determination was that the card (user) ID was valid ( 406 ), the rack PC 318 then sends ( 410 ) a message to the door controller 316 to prime the doors for opening (i.e. the locks 314 are electrically released; and the user can simply push the doors inward to release a latch (not shown), before opening the doors). Also, green LEDs ( 3 ), ( 4 ) and ( 5 ) are illuminated. As indicated at 412 , if the user has not pushed the doors to open within 30 seconds, processing returns to 408 .
[0074] Once the user does push the doors to open within 30 seconds, a beacon (LED) is set ( 414 ) flashing (signal to door controller 316 ) until the user shuts the door. At 416 a door closed signal has been received, indicating that the user has closed the doors. A message is sent to the door controller 316 to cease flashing the beacon. LEDs ( 4 ) and ( 5 ) are switched off, LED ( 2 ) (amber) illuminated, and the locks are activated to lock the doors.
[0075] Also at 416 , a request reading signal is sent to the multiplexer 302 , in response to which load cell readings are returned. Then, at 418 , updated multiplexer (digital weight) readings are sent to the rack PC 318 , and a LED and lock status signal is sent to the door controller 316 (i.e. returning the system to the “system ready” state.
[0076] As indicated at 420 , the doors are now locked, and LED ( 3 ) (“system ready”) illuminated.
[0077] The above-described process is applicable when a card is swiped after a predetermined interval (e.g. 15 seconds) after the doors were last closed. However, if there is a card swipe ( 422 ) within that period, a check ( 424 ) is made to determine whether it was by the same user as the previous occasion. If not, processing moves to 418 , and if so, processing moves to 410 .
[0078] Another procedure is indicated at 426 , 428 . This may be used, for example, if the rack PC 318 is for some reason non-operational. Here, an override key is used in the swipe card reader 114 ( FIG. 1 ), so that the doors can be opened ( 426 ). Then, the multiplexer 302 reads the weight readings from the load cells 110 , calculates the numbers of stock items removed, and books (stores in database in memory) the amount to the recorded owner of the key. Processing then proceeds to 420 .
[0079] FIG. 5 is a schematic block diagram showing the main electrical components in the stock monitoring system according to a second embodiment of the invention. This is the same as the first embodiment, except as described hereafter. Each load cell 110 (only one of which is shown) is coupled to a secondary controller 516 . The load cells 110 send analog weight readings to the secondary controller 516 and receive LED status signals from the secondary controller 516 . As indicated by the key 504 , each load cell 110 incorporates or is coupled to and associated with, a simple status indicator (e.g. using LEDs), including amber left LED 506 and a right red LED 508 . The key 504 is the same as key 304 in FIG. 3 .
[0080] Secondary controller 516 averages weight readings received from the load cell(s) 110 and converts the analog average reading to a digital reading. The secondary controller 516 transmits load cell digital readings and multiplexer status signals to a network switch 512 and receives therefrom online/offline request signals.
[0081] The secondary controller 516 incorporates or implements a multiplexor (not shown; see FIG. 3 ) and an access controller (not shown).
[0082] Referring briefly to FIG. 1 , the doors 104 can be locked using electrically controlled locks, designated 514 in FIG. 5 .
[0000] The locks 514 send lock status signals to a secondary controller 516 . Also, the locks 514 receive control signals from the secondary controller 516 —
“Set door lock” “Timeout” (after set period of time to relock doors), and “Release Door Lock”.
The secondary controller 516 may be any suitable microprocessor-based controller known in the art, for example model/part no. SS01, available from Inventor-e Ltd.
[0086] The secondary controller 516 sends lock status signals to the network switch 512 and receives therefrom, when appropriate, reboot messages. The network switch 512 is further coupled to a Controlling Software PC 518 (also referred to herein as Rack PC). This is a computer with standard (PC) architecture, with mountings, components/interfaces and specifications for use in industrial environments. Controlling Software PC 518 suitably
stores a database (of user IDs) and (optionally) charge code ID's for controlling door access processes load cell readings and converts them to quantities of parts/stock items stores Part IDs, part unit weights, user IDs and location IDs.
[0090] Optionally, the Controlling Software PC 518 is coupled to a web server 520 and sends stored and derived data thereto. In turn, the web server 520 is able to supply on demand (e.g. over internet and subject to password access) reports on data obtained from the rack PC, enabling a remote user (e.g. supplier) to view reports and download (e.g. into a suitable software package such as MS Excel).
[0091] The link between the secondary Controller 516 and the Controlling Software PC 518 may be a wired link, using suitable network hardware and protocols. Alternatively, a suitable wireless link may be used, e.g. GPRS.
[0092] FIG. 6 is a flow chart showing the main processing steps and operations in implementing stock monitoring according to an embodiment of the invention. Commencing at 602 , here the stock monitoring system is in a “system ready” state, ready for a user to attempt to access the cabinet 100 . In addition (see bottom left of FIG. 6 ), mounted in or on the cabinet 100 , coupled to the secondary controller 516 and visible to the user is a user display incorporating a number of LEDs. This includes upper red LED ( 1 ), a middle amber LED ( 2 ) and three green lower LEDS ( 3 ), ( 4 ), ( 5 ). In the “system ready” state, green LED ( 3 ) is illuminated.
[0093] At 604 , a user swipes his swipe card through the card reader ( 114 in FIG. 1 ). Then, the extracted card (user) ID is sent to the Controlling Software PC 518 , and a card acceptance/rejection message returned (depending on whether the user ID is an authorised/valid ID in the database stored on Controlling Software PC 518 ).
[0094] The two possibilities are indicated at 606 . As indicated at 608 (see FIG. 6( d )), if the card (ID) is not valid, then doors 104 are relocked, the Controlling Software PC 518 sends a message to the secondary controller 516 to display a predetermined indication. An LED status message is sent to the door controller to illuminate LED ( 2 ) for 4 seconds, prior to returning to the “system ready” state, with only LED ( 3 ) illuminated.
[0095] If the determination was that the card (user) ID was valid ( 606 ), depending on configuration, the user may be required to enter a charge code (see FIG. 6( c )). If this is setup, the user is asked ( 607 ) for this charge code, or if not, the system releases the locks ( 610 ). At 607 the user enters a charge code using the input device 116 . The latter can be a number of said devices including bar code reader, touch screen, keypad. Then, the extracted charge code is sent to the Controlling Software PC 518 , and a charge code acceptance/rejection message returned (depending on whether the charge code ID is an authorised/valid charge code in the database stored on Controlling Software PC 518 ).
[0096] The two possibilities are indicated at 609 . As indicated at 607 , if the charge code (ID) is not valid, then doors 104 do not have there locks released, the Controlling Software PC 518 sends a message to the secondary controller 516 to display a predetermined indication. At 607 ( FIG. 6( c )), if the user doesn't enter a charge code within 15 seconds, an LED status message is sent to the secondary controller 516 to illuminate LED ( 2 ) for 4 seconds, prior to returning to the “system ready” state, with only LED ( 3 ) illuminated. If the determination was that the charge code was valid ( 609 ) the system proceeds to ( 610 ).
[0097] The Controlling Software PC 518 then sends ( 610 ) a message to the secondary controller 516 to release the locks (i.e. the locks 514 are electrically released; and the user can simply pull the doors outward). Also, green LEDs ( 3 ), ( 4 ) and ( 5 ) are illuminated. As indicated at 612 , if the user has not pushed the doors to open within 30 seconds, processing returns to 608 .
[0098] Once the user does open the doors within 30 seconds, a beacon (LED) is set flashing 614 (signal to secondary controller 516 ) until the user shuts the door. At 616 a door closed signal has been received (see FIG. 6( f )), indicating that the user has closed the doors. A message is sent to the secondary controller 516 to cease flashing the beacon. LEDs ( 4 ) and ( 5 ) are switched off, LED ( 2 ) (amber) illuminated, and the locks are activated to lock the doors.
[0099] Also at 616 ( FIG. 6( f )), a request reading signal is sent to secondary Controller 516 , in response to which load cell readings are returned. Then, at 618 , updated digital weight readings are sent by secondary Controller to the Controlling Software PC 518 , and a LED and lock status signal is sent to the secondary controller 516 (i.e. returning the system to the “system ready” state).
[0100] As indicated at 620 , the doors are now locked, and LED ( 3 ) (“system ready”) illuminated.
[0101] The above-described process is applicable when a card is swiped after a predetermined interval (e.g. 15 seconds) after the doors were last closed. However, if there is a card swipe ( 622 ) within that period, a check ( 624 ) is made to determine whether it was by the same user as the previous occasion. If not, processing moves to 618 , and if so, processing moves to 610 .
[0102] Another procedure is indicated at 626 , 628 . This may be used, for example, if the Controlling Software PC 518 is for some reason non-operational. Here, a mechanical override key is used, so that the doors can be opened ( 626 ). Then, the Inventor-e Controller 516 reads the weight readings from the load cells 110 , calculates the numbers of stock items removed, and books (stores in database in memory) the amount to the recorded owner of the key. Processing then proceeds to 620 .
[0103] FIG. 7 shows a housing or cabinet employed in the stock monitoring system according to a third embodiment of the invention, employing compartmentalised drawers, with (a) a lateral front view of the drawers, and (b) plan and (c) side views of a drawer. As seen in FIG. 7( a ), a housing 700 is in the form of a chest of drawers, each drawer 704 being openable by the user using handle 703 . The housing 700 is suitably mounted on casters 701 . In addition, each drawer 704 has a respective drawer LED 707 . FIG. 7( b ) shows a single drawer 704 from above, the drawer 704 having a plurality (here 16 ) compartments, each being covered by a lockable lid 709 . In turn, a lid LED 711 is provided for each lid 709 , as a status indicator. The drawers 704 may also be lockable.
[0104] The side view of a drawer, in FIG. 7( c ), shows compartments or bins 708 , 708 ′, each containing parts or stock items 712 . Each compartment 708 has its own associated load cell 710 , for sensing weight changes due to addition/removal of parts. In some cases, a single load cell 710 ′ may be provided for measuring weight changes of two or more adjacent compartments 708 ′ (in which case the per unit part weight may be the same or different in the adjacent compartments 708 ′).
[0105] FIG. 8 is a schematic block diagram showing the main electrical components in the stock monitoring system according to the third embodiment. This is the same as for the second embodiment, except as described hereafter. In this embodiment, both compartment locks 814 and drawer locks 815 are provided, which lock compartments 708 , 708 ′ and drawers 704 , respectively, after they have (been) closed. The secondary controller 816 , incorporates multiplexor 802 and access controller 803 . The access controller—
sends LED status commands to the load cells & compartments, sends signals to the compartment locks to (i) timeout after a set period to relock a compartment, and (ii) lock/unlock compartments, and sends signals to the rawer locks to (i) timeout after a set period to relock a drawer, and (ii) set drawer locks
[0109] The access controller 803 sends signals indicating compartment lock status and drawer lock status to the network switch 812 . In turn, the network switch 812 sends signals indicating compartment lock status and drawer lock status to the controlling software (CS) PC 818 . The CS PC 818 sends signals in the other direction to (a) request cancelling of a drawer primed for opening and (b) lock/unlock a compartment.
[0110] FIG. 9 is a flow chart showing the main processing steps and operations in implementing stock monitoring according to the third embodiment. This is the same as for the second embodiment, except as described hereafter. Instead of lock/unlock, and other actions in relation to doors, the relevant action is taken in relation to drawers (steps 902 , 908 , 910 , 912 , 921 , 923 , 925 , 920 , 929 ) or compartments (lids) (steps 914 , 919 , 916 ).
[0111] In this third embodiment, the weight sensor based solution may utilise a standard tool cabinet e.g. Lista, Bott etc., with drawers that are compartmentalised to provide a high density storage solution with fast access. Each drawer has user access control, and there is also user defined access control at the compartment level. Segmentation of a drawers with the cabinet and use of (i) a weight sensor under the whole segmented drawer or (ii) a number of weight sensors to cover areas (more than one compartment) of the drawer, to control multiple dispensing of the same item from various compartments, may be employed. The compartments have restricted access via transparent openable/lockable lids on each, and the CS PC (Rack PC) records who has accessed the drawer and the individual compartment opened, using a smart button (Dallas key technology) or graphic user interface on the connected CS PC. The software can determine the part being accessed from its location and knows the part and the associated piece part weight of the item being taken, e.g. 9 grams. After the compartment lid has been closed, the CS PC records movement in inventory, e.g. if it is a 27 gram decrement in weight it will calculate that three of that particular part from that compartment have been taken. The user then moves on to obtain inventory from another compartment in the same drawer, or to another drawer, or simply shuts the drawer to close the transaction. This embodiment is ideal for the management of tools and smaller MRO components, where a range of products is required to be stored in a high density solution.
[0112] In the foregoing embodiment, one weight sensor may be used to manage multiple compartments, with the parts or stock items in each of those multiple compartments being identical or non-identical. Access control provides the software with the part and associated weight, which allows the weight sensor to record total weight change across all compartments it controls. The software knows the compartment accessed and part that has been taken, as the access control prevents other compartments from being opened until the compartment that has been opened is closed and the new weight sensor reading has been taken.
[0113] In a further embodiment, the storage cabinet is in the form of a locker-style cabinet (not dissimilar to those found in sports centres, clubs and schools). This is similar to the first embodiment, but has individual doors to shelves and/or bins, one door per bin or per shelf. This embodiment allows auditable issuance and return control on lockers, rather than having to physically key in the quantity taken or returned, as this relies on trust and user accuracy. Access to individual doors is via a Dallas (Smart) key, a smart key reader being coupled to the CS PC (rack PC). Supervisors have a master key that will allow access to all doors and will allow them to set up access to individual doors locally (on site) for their operatives.
[0114] Some functionalities of the stock control system will be summarised. The system utilises weight sensor technology to measure inventory (quantities of stock). Doors with enforced access control allow for user identification. The user swipes his identity card (with or without a PIN number) and this is validated against a user database. The locks on the storage cabinet are then ready to be released. In the first embodiment, the doors are then pushed to release the locks. If the doors are not pushed to open (first embodiment) or not pulled to open (second embodiment), the locks relock after a predetermined period. This prevents anyone else entering the cabinet on the identity card of the original person.
[0115] Measurements from the weight sensors are ignored with the exception of anti-tampering reports whilst the cabinet doors are open. The anti-tampering reports provide data on stock movement while the doors are open, e.g. if an individual takes an expensive item and replaces it with a lower value item of the same weight the main reporting system would not identify a stock movement against that individual user. However, the stock control system according to the invention reads the bins rapidly, so even the weight of a hand going in to take the item would be registered.
[0116] Users can take inventory and put it back but measurements taken from the load cells are not utilised within the software until the doors have been closed. The measurements from the load cells are then taken for a short predetermined time (e.g. one minute), and subsequent readings are ignored until the doors are opened and closed again. This means that drift in the weight sensors is minimised, as the time to read the weight sensors is finite. The quantity values are incremented or decremented from an original absolute value, which is measured when the cabinet is first loaded with inventory. Therefore the software only looks for changes in the weight of the bins over a very short time period and thus minimises the effect of drift, thereby maintaining high levels of accuracy on the inventory. The system also has the facility to do new absolute readings, which calculates the real time total weight of a bin. There is therefore the opportunity to compare or override the decremented readings from an original absolute value with new absolute readings.
[0117] When the doors have been closed the system reads the weight sensors for 15 seconds and does not allow any new users access to the storage cabinet in this period, although the same user can access in this period. This ensures accurate quantity changes and issuance and return quantities against users, as the system averages out peaks and troughs over this 15 second period to ensure accurate readings are taken. If another user does not swipe, readings will be taken for a one minute period to ensure the most accurate readings are taken. After one minute readings are ignored until the doors are opened again.
[0118] To restock the cabinet a supplier has a restock card. Physically this is the same as the issuance card (see below) but it identifies the user as a supplier or re-stocker and treats the data differently to materials being placed into cabinet with the issuance card. More particularly:
1) The issuance card is suitably an end user card and monitors material taken from the cabinet against individual employees. When an employee returns stock it is simply deducted from their account. For example, if an employee swipes and takes three pairs of gloves and an hour later returns two pairs, the net usage against their issuance account would be one pair of gloves. 2) The restock card (normally a supplier or third party outsourced replenishment service) treats items being put into the cabinet as new stock being introduced and automatically stores the quantity increases measured after the doors have been shut in a restock file. This means that an automated proof of delivery is recorded in computer memory. The cabinet records the quantities of items put into the cabinet together with the ID of the person that did the restock and the date and time of the transaction. This means performance measures can be automatically generated from the automated data capture
[0121] The system collects date and time stamped quantity change data and allocates it to a defined user (restocker or employee requiring issuance or return). The system then can send this data through, for example, an ADSL line or via GPRS. Messages of quantity changes are only sent one minute after the doors have been closed. This keeps message traffic to a minimum and therefore the cost of message traffic low. However, it means that quantity data is dynamically updated and available to remote users.
[0122] As used herein, “storage cabinet” refers to any housing or container in which bins, compartments, weight sensors, parts, tools or stock items are housed, including for example cabinets with doors and shelves or bins, chests of drawers, and locker style cabinets.
[0123] Additional particular embodiments are set out below.
[0124] 1. In a further embodiment, the system further includes a UI in the form of a touch screen, allowing a delivery (quantity of items for restocking a storage cabinet) to be allocated to a delivery note number. On restocking the supplier swipes their card through the card reader provided on the storage cabinet (and coupled directly or indirectly to the CS PC); the user is then validated and then prompted to enter a delivery note number, for use in database actions. The delivery note number can be keyed in via the touch screen or entered by barcode scanning. This allows access into the storage cabinet, and all quantities put into the storage cabinet will be allocated in the database to the delivery note number, as well as to the user. This allows delivery to a number of storage cabinets connected to the CS PC, and allows an administrator to validate the delivery against this supplier's delivery note number. In addition, this embodiment enables reports to be made available on order fulfillment, supplier performance and number of “stock outs” per supplier, and the duration of stock outs by supplier.
[0125] 2. In a further embodiment, in which the system further includes a touch screen, the user has the ability to display reports of quantities of items in other storage cabinets at the current storage cabinet touch screen, and if the item they are looking for is not available they have the ability to search from that storage cabinet which user had the last item. The user can also access videos (e.g. how to use a product), and or advertising, pictures and COSSH information at the touch screen of the storage cabinet.
[0126] 3. In a further embodiment, in which the system further includes a UI, an Exception Report is accessible, indicating items taken out of Job Number Scope (i.e. items that should not have been taken for the job associated with the job number). A list of parts or items can be allocated to a particular job number/charge code. When a user enters a job number/charge code, an exception report is generated if the user takes a part which is outside the scope for that job number/charge code.
[0127] 4. In a further embodiment, in which the system further includes a touch screen it may be possible to lock out users from a particular storage cabinet, in order to pre-allocate a product. When a user searches for a part from at a storage cabinet touch screen or kiosk, they have the ability to lock a particular storage cabinet for a time frame so that no other users can take that product. Once the user who has locked the storage cabinet has visited the storage cabinet and swiped their card at the card reader, the storage cabinet opens. If the user doesn't swipe their card at the storage cabinet within a predetermined time frame e.g. a number of seconds, or minutes or hours), then that storage cabinet becomes unlocked again.
[0128] 5. In a further embodiment, in which the system further includes a barcode reader on, adjacent or near a storage cabinet, and associated therewith and coupled to the CS PC, enhanced restocking is provided. Here, there is validation by bar coding of the product to the bar code on the appropriate bin in the storage cabinet. When the user scans the bar code on the product, the code is sent to the CS PC, and the CS PC responds with commands to controller to it light up the correct bin to place the product(s) into. The user then barcode scans the bin to tell the system which bin it is putting the product into. This bin then records a quantity. The benefit is that it ensures the correct part goes into the correct location.
[0129] 6. In a further embodiment, the system, in addition to load cell technology, further includes a RFID sensor on, adjacent or near a storage cabinet, and associated therewith and coupled to the CS PC. This system is able to enhance processing, to establish part quantity, when parts, stock items etc. are RFID tagged. When a part is RFID tagged its unit weight is also stored by the system. When a user takes a part from a bin having a weight sensor underneath it, the system checks that the RFID tag has left the storage cabinet, but also that the weight has been decremented by the part weight. Where the tag has left the storage cabinet but the weight has not been changed the part is still classed as been in the storage cabinet and an exception report can be generated/viewed, highlighting this problem. Alternatively, if a user takes a product but first rips off the RFID tag or prevents it from signalling the storage cabinet's RFID sensor as it's taken out, the decrement in weight signals that the product has gone. Thus, the RFID technology verifies the weight sensor technology and vice versa. The RFID tagging can also be used for the batch/lot control management of a particular part, i.e. identifying a specific batch/lot number to the user that takes the product.
[0130] In a further embodiment, more than one type of part/commodity can be stored on a weight sensor (load cell). The RFID tag identifies which part has been taken and the system knows the expected weight change of the parts taken. For example, if part A weighs 10 g and Part B weighs 7 g and the user tags 2× part A and 1× part B it knows from the RFID tags that the total weight taken from the bin should be 27 g. If it is not then the system reports that there is a variance.
[0131] In a further embodiment, RFID tagging also allows the system to check how long an item has been taken away and used for. For example, a tool such as a drill can be RFID tagged, and when it is taken from the storage cabinet, the system knows the time and also the time it is returned. This not only keeps a check of when an item needs to be re-calibrated but also the amount of time an employee has been using an item. This, for example, helps to ensure employees are not exposed to too much vibration from drill usage.
[0132] 7. In a further embodiment, the system can generate a negative usage report. Over a time period that is set by the user (for example 3 days) a report can be generated, indicating any users that have negative usage (i.e. user that have put more of a product back than they have taken away over the given period). This report assists in identifying users that are potentially tampering with the system.
[0133] For example for the usage date of two users below (2 nd and 4 th rows), there are negative readings that can be reported:
[0000]
User
Product
Usage
Time
John Brown
ABC
2
12 Feb. 2007
John Brown
ABC
−3
13 Feb. 2007
Fred Jones
EFG
1
14 Feb. 2007
Fred Jones
EFG
−10
13 Feb. 2007
Anthony Clarke
ABC
1
12 Feb. 2007
Anthony Clarke
ABC
2
13 Feb. 2007
[0000]
Report Inputs
Date:
To
from
Time Period
days
[0000]
Report Format
User
Product
Aggregated Usage
John Brown
ABC
−1
Fred Jones
EFG
−9
[0134] In a further embodiment, the system can store (in the database accessible by CS PC and associates with user ID) user size information, to restrict access to bins to specific users (who must enter their ID), or light up bins for the sizes of that specific user. This helps ensure users take the correct size products e.g. respirators, gloves, shoes etc., enhancing safety. | System(s) and method(s) for stock monitoring are provided. Stock monitoring system(s) may include e.g., a housings one or more doors disposed in or on the housing, a sensor for sensing the condition of the door(s) and providing a door closed signal indicative of the door(s) having been closed by a user; one or more containers for stock items, located within the housing, the or each container having associated therewith a weight sensor for providing a weight signal indicative of the current weight of the container, and control circuitry, coupled for communication with the weight sensor(s). Method(s) may include, e.g., receiving a door closed signal; receiving one or more weight signals; and determining, for the or each container, the number of stock items removed from the container(s) by the user, from the weight signal(s) occurring during a predetermined sensing period, the predetermined sensing period being dependent upon the door closed signal. | 6 |
FIELD OF THE INVENTION
This invention has to do with garments that incorporate elastic stretch fabric and fit tightly to the body, typically for sports use. Particular examples are described in relation to swimsuits, which is a preferred use. However, the concepts described can be applied to other sports and athletic garments including, for example, beach volley, waterpolo and triathlon wear.
BACKGROUND
A number of known sports garments, especially racing swimsuits, are made from elasticated stretch fabric which fits closely and tightly against the body. In recent years use has been made of various fabrics with high elastane content having a high stretch constant to press more firmly against the body surface for a given degree of stretch. In racing swimsuits this reduces the entry of water between the suit and body—a source of drag—and avoids the sliding of the fabric over the skin. It can also reduce muscle vibration which is believed to be a cause of fatigue and body drag in swimming.
In our earlier applications EP-A-1110464 and EP-A-1250858 we describe swimsuits that provide an improved, highly-tensioned fit over the body, especially lower back and abdominal fit, using a special disposition of seams joining panels of elasticated stretch fabric that make up the swimsuit. The introduction of a seam across a span of stretch fabric was shown to reduce the stretchability, i.e. potentially increase a degree of tensioning, in a direction transverse to the seam.
As an additional measure to minimise the entry of water between the suit and body, EP-A-0411351 proposes the application of sheets of an air-tight and waterproof material to limited areas on a swimsuit adjacent openings (e.g. arm and neck openings). This is said to help prevent water intruding through the openings and the material of the swimsuit immediately adjacent the openings.
SUMMARY OF THE INVENTION
The present invention is generally concerned with structures for swimsuits (and other tight-fitting outer garments, especially sports garments) that can offer improved performance for competitive swimmers through a reduction in surface drag, a reduction in form drag and/or improved stability in the water. Another general proposition of the present invention is to offer swimsuits that have stroke-specific tailoring and that can serve to support accurate execution of the stroke.
In a first aspect the invention provides a garment having:
a base layer of stretchable elasticated fabric that covers at least the torso; and
a plurality of panels laminated on the outer surface of the base layer.
Preferably the panels cover 10% or more of the torso.
More preferably the panels cover 15%, 20%, 25%, 30%, 35%, 40%, 45% or even 50% or more of the torso. In some preferred embodiments, the panels cover 20% or more of the rear of the torso and may cover as much 30%, 40% or even 50% or more of the rear of the torso. It is particularly preferred that the panels cover at least 50% of the front of the torso and in some embodiments may cover as much as 60%, 70% or 80% or more of the front of the torso. In some embodiments the panels will cover more of the front of the torso than of the rear of the torso.
Competition swimsuits (and some other sports garments) often also cover either the whole or part of an athelete's legs. Applying the principles of the invention to such suits, the legs of the suit preferably also have one or more panels laminated on their outer surface. The panels may cover 20%, 25%, 30%, 35%, 40%, 45%, 50% or more of each leg and in some embodiments cover 75% or more.
Whilst it would be possible also to apply the principles of the invention to the arms of a suit (where present), it is generally more preferable to ensure that the athlete's arms have as much freedom as possible to move. Preferably, therefore, where the suit has arms, the arms of the suit are made from a lightweight fabric (either the same fabric as the suit torso or a lighter weight fabric) and there are no panels laminated onto the arms.
More generally, the swimsuit (or other sports wear) may cover e.g.
(i) the whole body, including the full length of the arms and legs;
(ii) as (i) but not the arms;
(iii) as (i) or (ii) but not the legs, or the legs only down to knee-length;
(iv) the torso only, i.e. no arms or legs;
(v) the midriff and legs only, either full-length (long-john), shorts or knee-shorts.
In a second aspect the invention provides a garment having a base layer of stretchable elasticated fabric that covers at least the legs and a plurality of panels laminated on the outer surface of the base layer.
The panels may cover 20% or more of the legs of the suit.
In this aspect, the panels preferably cover 25%, 30%, 35%, 40%, 45%, 50% or more of each leg of the suit and in some embodiments cover 75% or more.
The panels applied to the torso and/or limbs of suits according to the present invention are preferably formed of a material having a higher stretch constant than that of the underlying base layer and are applied to areas of the torso in which it is desired for the suit to be more tensioned when worn to provide greater support and/or to reduce the form of the underlying part of the athlete's (e.g. swimmer's) torso, to reduce form drag in the water.
The panels are preferably formed of a material having an outer surface that is more ‘slippery’ (i.e. exhibits lower surface drag in water) than the underlying base layer. In this way, the surface drag of the overall suit is reduced by application of the panels, especially where the panels cover a substantial percentage of the surface of the suit.
The material for the panels is preferably selected to combine both of the above benefits.
Suitable materials for the panels include polyurethane sheet material. The properties of the polyurethane material (or other equivalent material) can be selected to give the desired stretch characteristics.
For currently envisaged applications, preferred properties include a material weight in the range 70 g/m 2 to 110 g/m 2 , more preferably 80 g/m 2 to 100 g/m 2 , even more preferably 85 g/m 2 to 95 g/m 2 , for example 90 g/m 2 . The thickness of the sheet material is preferably in the range 50 microns to 100 microns, more preferably 60 microns to 90 microns and even more preferably 70 microns to 80 microns, for example 75 or 76 microns.
Exemplary polyurethane materials include two layer polyurethane films, with an adhesive layer (for adhering to the underlying garment fabric) and a thick film face side layer, which may have a matt finish. The adhesive layer may provide ⅔ of the overall sheet thickness. The adhesive preferably has a softening point in the range 60° C. to 80° C., for example 72° C. (TMA onset temperature). The service temperature range of the adhesive is preferably at least −20° C. to 60° C. and more preferably −40° C. to 75° C.
Whilst the panels may all have the same properties, in some applications they may advantageously have different properties from one another (e.g. different stretch constants, for instance as a result of having different weights and/or thicknesses) to provide greater tailoring of the properties of the suit over the athlete's body.
The elastic stretch fabric used to make the suit may be of any suitable kind. Fabrics of high stretch constant, e.g. polyester elastanes as conventionally used for making high-performance swimwear, are within the skilled person's routine knowledge.
The more of the surface of swimsuit (or other sports wear) is covered with a low drag material the greater will be the improvements (reduction) in surface drag. However, the present inventors have recognised that low drag materials very often have very high stretch constants and/or very low water permeability. Especially in competition swimsuits, it is important that there is sufficient ‘give’ in the suit to allow the swimmer to efficiently execute their stroke. If a suit is too highly tensioned then energy will be wasted overcoming the resistance the suit offers to the swimmer's movements. It is also important that water can escape from within the suit to avoid a build up of water between the suit and the swimmer's skin, which results in increased drag.
We propose, therefore, to retain specific areas of the swimsuit free of panels to enable venting of water from within the suit and/or efficient stroke execution. Put another way, the panels are preferably located on specific areas of the base layer to maximise the benefits of reduced surface and form drag, increased support and/or compression of muscles to improve power, whilst minimising the resistance the suit provides to articulations of limbs and bending or twisting of the torso necessary for execution of the swimming stroke. Similar principles can be applied to the design of garments for other sports activities requiring particular body movements/forms.
Whilst some optimisation of the position of the panels to balance these potentially conflicting requirements is possible in a generic suit (i.e. one intended for all strokes), we have found that more optimal results can be achieved by designing the layout of the panels across the surface of the suit dependent on the requirements of specific strokes.
One or any combination of two or more of the following panel locations are preferred (the suggested function of each panel being in addition to a potential reduction in surface drag and form drag that all the panels can provide):
To support a swimmer's core, a panel on the front of the suit covering the swimmer's abdomen. The panel may be generally rhomboidal, extending down to the crotch and up to the sternum. Also to support the swimmer's core, one or more panels extending across the swimmer's lumbar region. A single band across the lumbar region may suffice, although it may be necessary to provide a central split extending from the upper edge of the band at least part way down to accommodate the lower end of a zip fastener, typically positioned down the centre of the swimmer's back. To compress the buttocks in order to reduce form drag, one or more panels extending over the buttocks. Conveniently the lumbar panel, where used, may extend down over the buttocks to provide the desired compression. To compress the chest, particularly for female swimmers, a panel or panels covering the chest. The configuration of the panel(s) is chosen to alter the form of the chest without restricting lung function to any significant degree. Preferably two panels are used, one to either side of the sternum. They may extend from the neckline down to approximately the bottom of the rib cage. Where an abdominal panel is used, they may extend respectively to the left and right medial sides of the abdominal panel. For strokes with a leg kick in which the legs remain generally straight (freestyle, backstroke, butterfly), to support the legs, a panel extending over the quadriceps muscle group on the front of the thigh, a panel extending over the hamstring muscle group on the rear of the thigh, upper leg and panels on the front and rear of the lower part of each leg (shin and calf), preferably in each case covering about 80% or more of the relevant muscle group. Preferably a band around each knee is kept free of any panels to allow some flexing of the knee. For breaststroke, to support the breaststroke leg kick, a series of panels on the legs similar to those described above are provided. However, the calf panels are preferably shaped to wrap further forward around the lateral side of the leg below the knee and at the ankle than in the middle of the calf. The panel on the front of the lower leg is correspondingly foreshortened laterally to retain a spacing between the calf panel and the lower front leg panel. The quadriceps panels preferably stop at the hip so as not to hinder articulation of the hip joint. The lower lateral corner of each hamstring panel preferably also wraps around towards the front of the leg just above the knee. In some cases it will be preferable to cut off the legs of the suit above the knees to give greater freedom of movement for the swimmer's lower legs when executing the breaststroke kick. To provide support for the back without hindering motion in strokes that require twisting of the upper part of the trunk (e.g. freestyle and backstroke), a pair of panels are preferably provided on the back extending from the centre of the back in the lumbar region upwardly towards the shoulders. The panels may be strip shaped and may be angled laterally outwardly up the back, so they diverge at their upper ends. Conveniently, these back supporting panels may be formed in one piece with the lumbar panel where provided. The lateral sides of the trunk below the armpits are free of panels. To provide support for the back without hindering motion in strokes that require arching of the back without lateral movement (e.g. breaststroke and butterfly), a pair of panels may be provided on the back of the suit, spaced to either side of the spine, to wrap around from the back to the lateral sides of the trunk below the arms. This provides good support, minimising lateral movement, whilst leaving a relatively broad area spanning the spine free from panels so as not to provide excess resistance to the arching of the back.
Embodiments of the present invention may employ panels in one or any combination of two or more of the positions noted above.
One notable source of surface drag in known competition swimsuits is the zip fastener. Typically the zip fastener extends vertically along the centre of the back of the swimsuit from the neck opening down to the lumbar region. In a further development the present invention provides a zip fastener that has a lower external profile than conventional zip fasteners. To achieve a lower external profile, the zip may be fastened to the suit (or other garment) with what would normally be the underside of the zip facing outwards, so that the flat underside of the zip teeth is facing externally, whereas the raised teeth themselves face to the inside of the suit. The adjacent fabric of the suit preferably also extends close to the centre line of the zip so that only a small band (e.g. less than 5, 4, 3, 2 or even 1 mm) of the zip tape is exposed to either side of the join line of the zip. The edges of the suit fabric adjacent the zip fastener are preferably laser cut to give a sharp edge. The zip tape is preferably bonded to the suit fabric, avoiding the additional drag that can be created with stitching.
This zip fastener arrangement can be used to advantage in other swimsuits (and other sports garments), especially where minimising surface drag is an important factor, independently of the other aspects of the invention discussed above.
It is also important to ensure that the edges of the suit at openings, e.g. neck openings, ankles, shoulder, wrists, etc fit snugly and comfortably against the athlete's body. Conventionally, the openings of swimsuits and other sports garments are hemmed with stitching to provide the desired fit. However, this creates a raised area on the outside surface of the suit, increasing drag. Swimsuits (or other garments) according to preferred embodiments of the present invention preferably use an edging strip mounted around the openings on the inside surface of the suit. The edging strip is preferably bonded to the inside surface of the suit. Suitable materials for the edging strip include neoprene. The weight and thickness of the edging strip material can be selected to provide a snug fit to the wearer's body.
These edging strips can be used to advantage in any swimsuits (or other garments), independently of the other aspects of the invention set forth above.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are now described by way of example as applied to racing swimsuits, with reference to the accompanying drawings in which
FIG. 1 is a front view of a full body suit with no arms, adapted especially for the freestyle stroke;
FIG. 2 is a back view of the FIG. 1 suit;
FIG. 3 is a side view of the FIG. 1 suit;
FIG. 4 is a front view of a full body suit with no arms, adapted especially for the breaststroke;
FIG. 5 is a back view of the FIG. 4 suit;
FIG. 6 is a side view of the FIG. 4 suit;
FIG. 7 is a front view of a full body suit with no arms, adapted especially for the backstroke;
FIG. 8 is a back view of the FIG. 7 suit;
FIG. 9 is a side view of the FIG. 7 suit;
FIG. 10 is a front view of a full body suit with no arms, adapted especially for the butterfly stroke;
FIG. 11 is a back view of the FIG. 10 suit;
FIG. 12 is a side view of the FIG. 10 suit;
FIG. 13 is a schematic illustration of a low profile zip fastener used in the suits of the preceding figures;
FIG. 14 is a schematic illustration of edging strips used at openings of the suits of FIGS. 1 to 12 .
FIG. 15 shows front, side and back views of a full body suit, including arms, adapted especially for the freestyle stroke for a male swimmer;
FIG. 16 shows front, side and back views of another full body suit, including arms, adapted especially for the freestyle stroke for a male swimmer;
FIG. 17 shows front, side and back views of a full body suit, with no arms, adapted especially for the freestyle stroke for a male swimmer;
FIG. 18 shows front, side and back views of another full body suit, with no arms, adapted especially for the freestyle stroke for a male swimmer;
FIG. 19 shows front, side and back views of a legskin suit adapted especially for the freestyle stroke for a male swimmer;
FIG. 20 shows front, side and back views of a ‘jammer’ style suit, adapted especially for the freestyle stroke for a male swimmer;
FIG. 21 shows front, side and back views of a kneeskin suit, adapted especially for the breaststroke for a male swimmer;
FIG. 22 shows front, side and back views of another kneeskin suit, adapted especially for the breaststroke stroke for a male swimmer;
FIG. 23 shows front, side and back views of a full body suit, including arms, adapted especially for the freestyle stroke for a female swimmer;
FIG. 24 shows front, side and back views of another full body suit, including arms, adapted especially for the freestyle stroke for a female swimmer;
FIG. 25 shows front, side and back views of a full body suit, with no arms, adapted especially for the freestyle stroke for a female swimmer;
FIG. 26 shows front, side and back views of another full body suit, with no arms, adapted especially for the freestyle stroke for a female swimmer;
FIG. 27 shows front, side and back views of a ‘recordbreaker body’ style suit, adapted especially for the freestyle stroke for a female swimmer;
FIG. 28 shows front, side and back views of another ‘recordbreaker body’ style suit, adapted especially for the freestyle stroke for a female swimmer;
FIG. 29 shows front, side and back views of a ‘recordbreaker’ kneeskin suit, adapted especially for the freestyle stroke for a female swimmer;
FIG. 30 shows front, side and back views of another ‘recordbreaker’ kneeskin suit, adapted especially for the freestyle stroke for a female swimmer;
FIG. 31 shows front, side and back views of a ‘recordbreaker’ style suit, adapted especially for the freestyle stroke for a female swimmer;
FIG. 32 shows front, side and back views of another ‘recordbreaker’ style suit, adapted especially for the freestyle stroke for a female swimmer;
FIG. 33 shows front, side and back views of a kneeskin suit, adapted especially for the breaststroke for a female swimmer; and
FIG. 34 shows front, side and back views of another kneeskin suit, adapted especially for the breaststroke stroke for a female swimmer;
DETAILED DESCRIPTION
In general terms, we have found that, compared with prior art swimsuits formed from a single layer of fabric, superior results can be achieved by applying (laminating) panels of less elastic (higher stretch constant) and/or more ‘slippery’ (i.e. lower surface drag to reduce resistance in water) material in specific locations on a base layer fabric that gives the swimsuit its overall form.
This may be somewhat surprising to those skilled in the art because trends in the field are towards single layer fabric suits with low profile seams in order to minimize surface drag. The present inventors have recognised, however, that there are limits to the performance improvements that can be achieved with a single layer approach. More specifically, they have recognised that whilst performance can be enhanced, as described for example in our earlier EP-A-1110464, by increasing the tension in the suit when worn to ensure a closer fit to the swimmer's body, there is a point at which the increased tension begins to hinder the swimmer's performance of their swimming stroke as the suit restricts their movement. By selectively laminating panels on the outer surface regions of the base layer fabric of the swimsuit, as the inventors now propose, it becomes possible to offer performance enhancements over single layer suits, whist retaining many of the benefits of such single layer suits by appropriate placement of the panels so as not to inhibit the articulation of the swimmer's limbs and torso necessary for a particular stroke.
The inventors have identified three distinct potential functional benefits that can be achieved with this topical lamination of panels (i.e. application of the panels at positions on the suit corresponding to selected, localised areas of the body when the suit is worn).
The first is an overall reduction in surface drag by using panels that are more ‘slippery’ in water than the fabric of the underlying base layer.
The second potential benefit is a reduction in form drag by applying panels at body ‘high points’, such as buttocks and breasts, to provide an area of increased stretch constant, the resultant higher tension in the suit when worn applying greater compressive forces to the high points to reduce their form. Preferably the panel material itself has a higher stretch constant than the fabric of the underlying base layer. Some improvement in the tensioning of the area of the suit to which the panel is applied is seen, however, even with panels of material having the same or a lower stretch constant than the base layer (the overall tension being a sum of the forces generated in the base layer and the panel).
The third potential benefit is to help generate an increase in muscle power generation by using panels to create more highly tensioned areas of the suit adjacent (preferably surrounding) specific muscles or muscle groups to apply compression to them.
Advantageously, two or all three of these benefits can be obtained by the use of a single panel. For instance, if a panel is formed from a low drag, high stretch constant material it can serve to reduce surface drag in the region of the suit to which it is applied as well as to apply compressive forces to muscles and/or body high points.
Furthermore, by careful study of various swimming strokes, the inventors have realised that the configuration of the laminated panels can be designed not only to avoid unduly constraining the swimmer but actually to support the swimmer through the stroke by providing enhanced core stability and encouraging accuracy of stroke execution by offering less resistance to movement of the swimmers limbs and torso for the motions required for accurate stroke execution. This has led the inventors to develop a series of swimsuits specifically adapted for the different swimming strokes, as illustrated in the accompanying figures.
The illustrated suits are all made from a base layer of high stretch constant elastane fabric of a known kind.
The base layer may be formed from multiple sections joined to one another. The sections may be joined by stitching as described, for example, in our EP-A-1110464. More preferably, however, adjacent sections of the base layer are bonded to one another. Such bonded seams have been found to have particularly low profiles and resultant low drag properties in water.
As is normal, the suits have zip fasteners to allow a swimmer to don and take off the suit. Preferably the zip fastener has a low profile and is bonded to the sections of the suit that it joins to minimise the drag. As can be seen in FIG. 13 , to achieve a lower external profile, the zip fastener is bonded to the suit with what would normally be the underside of the zip facing outwards, so that the flat underside of the zip teeth is facing externally, whereas the raised teeth themselves face to the inside of the suit. The adjacent fabric of the suit preferably extends close to the centre line of the zip so that only a small band (no more than about 2 mm) of the zip tape is exposed to either side of the join line of the zip.
In the suits intended for freestyle, breaststroke and butterfly, the zip fastener extends down the centre of the back of the suit in a normal manner. In the backstroke suit the zip fastener may alternatively be located on the front of the suit (e.g. down the middle of the chest/abdomen). However, the low profile nature of the zip fastener means that even for the back stroke suit it can be located on the swimmer's back without significantly increasing the drag in the water.
It is normal to apply an edging strip to edges of a swimsuit at openings (e.g. neck, arms, ankles). In the illustrated suits a thin polyurethane tape is preferably used for edging the openings to ensure that the edging has a low profile. Alternatively the edging may be formed from neoprene. Preferably it is bonded to the inside surface of the suit adjacent the openings, as shown schematically in FIG. 14 .
The suits have panels of a polyurethane material laminated on the outer surface of the base layer at selected locations, in accordance with the present invention.
In this example, the polyurethane material is a two layer polyurethane film, with an adhesive layer (for adhering to the underlying garment fabric) and a thick film face side layer, which may have a matt finish. The material has a weight of about 90 g/m 2 and an overall thickness of about 76 microns, with the adhesive layer providing ⅔ of the overall thickness. The adhesive has a softening point of 72° C. (TMA onset temperature) and a service temperature range of −40° C. to 75° C.
The suits of the various examples differ in the configuration of the laminated panels, the configuration in each case being selected to support a specific swimming stroke, as discussed in more detail below.
FIGS. 1 to 3 show a body suit 2 , the base layer 4 of which covers and fits closely over the entire torso 6 and also the legs 8 to the ankles. In this example the suit has no arms but the principles illustrated are applicable also to arms with suits. The suit is especially adapted for use by freestyle swimmers.
A characteristic feature of the suit is a unique disposition of multiple specially-shaped panels laminated on the outer surface of the suit, which provide areas of reduced surface drag and/or greater compression and/or support of a swimmer's body without inhibiting the swimmer's stroke. In fact, the selective support provided by the laminated panels can help support and maintain the form of the swimmer's stroke.
The torso region 6 of the suit 2 has three panels on the front, an abdominal panel 10 and left- and right-side chest panels 12 , 14 . On the rear or the torso region 6 there are left- and right-side lumbar panels 16 , 18 and left- and right-side back panels 20 , 22 , which in this example extend from and are formed integrally with the lumbar panels 16 , 18 .
The abdominal panel 10 is generally rhomboidal in shape. A bottom corner 101 of the panel 10 extends down to the crotch region 61 of the suit. A top corner 102 of the panel extends up to the sternum region 62 . Left and right corners 103 , 104 of the panel extend laterally towards the side of the torso region 6 , terminating just short of the mid-line 63 of the side of the torso. The abdominal panel 10 provides an area of low surface drag as well as providing a highly tensioned region to give greater core stability.
The chest panels 12 , 14 are symmetrical with one another about the centre line of the front of the suit. The right-side chest panel 14 is generally triangular in shape. It has a medial side edge 141 that extends from the neck opening 24 down to a point at the bottom end 142 of the panel adjacent to but spaced from the left-side corner 104 of the abdominal panel 10 . The side edge 141 is slightly convex in shape. A lateral side edge 143 of the chest panel 14 extends generally vertically from the bottom end 142 of the chest panel 14 to a position close to the lower edge of the right arm opening 26 of the suit. A top side edge 144 of the chest panel 14 extends in a convex curve from the top end of the lateral side edge to the neck opening 24 at a point close to but laterally outward from the top end of the medial side edge 141 . The left-side chest panel 12 is a mirror image of the right-side chest panel 14 .
The chest panels 12 , 14 are configured to avoid restricting the swimmer's lung function. This may be achieved through appropriate shaping of the panels and/or through selection of a material with an appropriate stretch constant. The material may be the same as used for other panels on the suit. If needs be, however, the chest panels may be formed of a material having a lower stretch constant that the abdominal panel 10 (and the other panels discussed below) so they are less tensioned when the suit is worn in order that they do not overly restrict the swimmer's breathing. The chest panels 12 , 14 serve to flatten the swimmer's chest, reducing form drag, as well as providing further areas of low surface drag.
The lumbar panels 16 , 18 are generally trapezoidal in shape, with (taking the right-side panel as an example) generally vertical medial and lateral side edges 181 , 182 and top and bottom edges 183 , 184 that rise upwardly on the torso in the lateral direction. The lower part of the lumbar panel 18 extends down over the buttock area 28 . The bottom edge 184 is slightly convexly curved to generally follow the lower edge of the swimmer's buttock (gluteus maximus). The top edge 183 is generally in line with the lowermost rib. The left-side lumbar panel 16 is a mirror image of the right-side panel 18 .
The two lumbar panels 16 , 18 meet one another at a lower end portion of their respective medial sides edges, at the crotch region 61 . The medial side edges diverge slightly from one another towards the upper edge of the panels.
The lumbar panels 16 , 18 provide highly tensioned areas to support the lumbar region, improving core stability. They also compress the swimmer's buttocks, reducing form drag and provide large surface areas of the suit with low surface drag.
The right-side back panel 22 has the form of narrow oblong extending from the centre line of the back of the suit adjacent the top edge of the lumbar panel 18 diagonally outwardly across the back to the arm opening 26 , generally adjacent a lower edge of the scapula. The upper end 221 of the back panel 22 is laterally spaced from the centre line of the back of suit by a distance that is about one third of the distance between the back centre line and the centre line 63 of the right-side of the suit. This leaves a relatively large panel-free torso portion 66 of the suit under the arm opening 26 between the tope edge 183 of the lumbar pad, the lateral side edge 143 of the right-side chest panel 14 and the back panel 22 . In use this arrangement provides support for the upper back whilst enabling relatively free twisting of the upper back and shoulder girdle of a swimmer, necessary for execution of the freestyle (front crawl) stroke. This, in turn, encourages correct execution of the stroke.
The left-side back panel 20 is a mirror image of the right-side back panel 22 .
The illustrated suit also has a pair of panels applied to each leg. On each leg there is an upper leg panel that wraps around the inside of the leg from the front to the rear, comprising a quadriceps (‘quad’) panel portion 30 , 32 on the front of the thigh (upper leg) and a hamstring panel portion 34 , 36 on the rear of the upper leg. On each leg there is also a lower leg panel, which also wraps around the inside of the leg, comprising a calf panel portion 38 , 40 on the rear of the lower leg and a shin panel portion 42 , 44 on the front of the lower leg. The panels on the left leg are a mirror image of the panels on the right leg.
Looking at the right leg, the quad panel portion 30 has a lateral side edge 301 that extends in a convex sweeping line from the inside of the leg just above the patella out to the lateral side of the leg and up to a point 302 at the hip, generally following the outline of the quadriceps muscle group. A top edge 303 of the quad panel portion extends from the top point 302 to an inner leg region 68 adjacent the crotch region 61 . The quad panel portion 30 covers substantially the whole of the quadriceps muscle group, applying compression to the muscles to enhance the power generated by them. The panel also helps to reduce surface drag over the front of the upper leg.
The hamstring panel portion 36 is generally trapezoidal in shape. It extends across the full width of the rear upper part of the leg, extends down to just above the rear of the knee joint at the inside of the leg and extends up to just below the buttock. The upper edge 361 of the panel portion 36 is convexly curved and is spaced from but closely follows the line of the bottom edge 184 of the lumbar panel 18 . The bottom edge 362 of the hamstring panel portion is gently curved, concavely, to rise up towards the lateral side of the leg where it merges into the lateral side edge 363 , which extends, also in a gently convex curve, to meet the lateral end of the upper edge 361 at an acute angle.
The hamstring panel portion applies compression to the hamstring muscles in use to enhance the power generated by those muscles. It also helps to reduce surface drag over the rear of the leg.
The quadriceps and hamstring panel portions 30 , 36 wrap around the inside of the leg to meet one another, forming one continuous panel wrapping around the inside of the upper leg. Opposite ends of the panel terminate on the outside of the leg, spaced from one another to either side of a seam running down the outside of the leg.
The calf panel portion 40 and shin panel portion 42 between them extend most of the way around the lower leg from just below the knee to the ankle. As with the upper leg panel portions, these panel portions wrap around the inside of the leg to form a continuous panel with opposite ends terminating on the outside of the leg to either side of the leg seam.
Both lower leg panel portions 40 , 42 extend slightly higher up the lateral side of the leg than the medial side of the leg. The upper edge 401 of the calf panel portion is convexly curved to generally follow the shape of the underlying muscles in the calf (in particular the gastrocnemius muscle). The upper edge 421 of the shin panel portion 42 , on the other hand, is concavely curved to provide clearance around the lower part of the front of the knee joint. The bottom edges 402 , 422 of the calf and shin panel portions 40 , 42 are generally horizontal and in-line with one another.
The calf panel portion 40 applies compression to the muscles of the calf (gastrocnemius and soleus muscles) and the shin panel portion 42 covers and applies compression to the tibialis anterior muscle. This compression can increase the power generated by the muscles. The panel portions 40 , 42 also reduce the surface drag over the lower leg.
A band 69 around each knee is kept free or any panels to allow some flexing of the knee.
Turning to FIGS. 4 to 6 , a suit specifically adapted for breaststroke is shown. The underlying base layer of the suit is identical to the freestyle suit described above. The disposition of the panels laminated on the outer surface of the base layer differs, however.
Some of the panels are common to both suits. For example, the breaststroke suit has the same abdominal and chest panels 10 , 12 , 14 as the freestyle suit, providing core stability, improved form (for a reduction in form drag) of the chest and a reduction in surface drag of the front of the torso in the same manner as described above. The suit also has the same overall layout of panels as the freestyle suit but the specific form of the panels is adapted to be more tailored to the motions of the breaststroke.
Looking at FIG. 5 , for example, it can be seen that whilst the lumbar panels 16 ′, 18 ′ have the same form as those of the freestyle suit described above, the back panels 20 ′, 22 ′ formed integrally with the lumbar panels 16 ′, 20 ′ are very different in form to those of the freestyle suit. Specifically, the right-side back panel 22 ′ extends from the upper edge of the lumbar panel 18 ′ up the lateral side of the back to the arm opening 26 , wrapping around the side of the torso to close to the mid-line of the torso side. The left-side back panel 20 ′ is a mirror image of the right-side panel 22 ′.
There is a broad, panel free strip 70 extending down the centre of the back from the neck opening 24 of the suit to the top edge of the lumbar panels 16 ′, 22 ′.
This specific configuration of the back panels helps to retain the swimmer's torso in-line in the water, resisting twisting of the torso, whilst allowing the arching of the swimmer's back needed for execution of the stroke.
The leg panels 30 ′, 32 ′, 34 ′, 36 ′, 38 ′, 40 ′, 42 ′, 44 ′ of the breaststroke suit also differ in shape to those of the freestyle suit of FIGS. 1 to 3 . Looking at the right leg (the left leg is a mirror image), the calf panel 40 ′ is shaped to wrap further forward around the lateral side of the leg below the knee and at the ankle than in the middle of the calf. The shin panel 42 ′ is correspondingly foreshortened laterally to retain a spacing between the calf panel 40 ′ and the shin panel 42 ′. The quad panel 30 ′ does not extend as far up as that on the freestyle suit. It stops at the hip so as not to hinder the greater articulation of the hip joint required in the breaststroke leg movement. The lower lateral corner of the hamstring panel 36 ′ also wraps around towards the front of the leg just above the knee.
As seen best in FIG. 4 , the combination of the upper, medial portion 428 of the shin panel 42 ′, the upper lateral portion 408 of the calf panel 40 ′, the lower medial portion 308 of the quad panel 30 ′ and the lower lateral portion 368 of the hamstring panel 36 ′ cradle the front of the knee joint to better support its articulation during the breaststroke leg movement.
In another suit adapted for breaststroke (not illustrated) the legs are cut off just above the knee. This gives greater freedom for movement of the swimmer's legs when executing the breaststroke leg kick. Otherwise it is identical to the suit of FIGS. 4 to 6 .
FIGS. 7 to 9 show another suit in accordance with an embodiment of the invention especially adapted for backstroke. The panels 10 - 22 , 30 - 44 laminated on the base layer of the suit are the same as those used in the freestyle suit of FIGS. 1 to 3 . In this backstroke suit, however, unlike the freestyle suit, the zip fastener 80 extends down the centre of the front of the suit.
FIGS. 10 to 12 show another suit in accordance with an embodiment of the invention especially adapted for the butterfly stroke. The abdominal, chest and leg panels, 10 , 13 , 14 , 30 - 44 are as in the freestyle and backstroke suits described above. The lumbar and back panels 16 ′, 18 ′, 20 ′, 22 ′ are as in the breaststroke suit of FIGS. 4 to 6 .
FIGS. 15 to 34 show further examples of different styles of swimsuit having panels laminated to the outside surface of the base layer in accordance with embodiments of the invention. In these drawings the white areas indicate the base layer fabric, the light grey shaded areas are the laminated panels and the dark grey shading is used to illustrate arms made from a fabric that is different from the base layer fabric.
As seen in the figures, the suits of FIGS. 15 to 34 differ in style and/or in the number of panels that are laminated on the base layer.
For example, comparing FIGS. 15 and 16 , which show the same style of full body suit (with arms), it can be seen that whereas the suit of FIG. 15 has panels largely as described above (save for the absence of lower leg panels), the suit of FIG. 16 does not have back panels or lumbar panels and nor does it have an abdominal panel.
Similarly, it can be seen that the suits of FIGS. 18 , 22 , 24 , 26 , 28 , 30 , 32 and 34 , also do not have back, lumbar and abdominal panels. The suits of FIGS. 22 , 30 and 34 additionally lack hamstring panels.
FIGS. 19 and 20 show leg only suits for male swimmers. In FIG. 19 , the suit extends the full length of the swimmers legs (a so called “legskin”). Upper leg panels are shown, along with truncated (at the upper edge) addominal and lumbar panels. In this example there are no lower leg panels but other embodiments might include lower leg panels, for example of the form seen in FIGS. 1 to 3 . The FIG. 20 suit is a so called “jammer”, extending down only as far as the knees.
The skilled person will appreciate that the suits illustrated in the figures and described above are examples embodying inventive concepts described herein and that many and various modifications to the specifically described suits, including the number, disposition and shape of the laminated panels can be made without departing from the invention. The principles exemplified above can also be applied to other specialist sports garments, especially wet sports such as waterpolo and triathlon and beach sports such as beach volley. | This application describes garments ( 2 ), for example swim suits or other sports or athletic garments, in which a plurality of panels ( 10 - 22 & 30 - 44 ) are laminated on the outer surface of a base layer ( 4 ) of stretchable elasticated fabric to offer (in the case of a swim suit) improved performance for competitive swimmers through a reduction in surface drag, a reduction in form drag and/or improved stability in the water. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates in general to the coating arts and, more particularly, to fine powders especially suited to the generation of coatings by plasma spray techniques.
Plasma spray coating techniques are well recognized in the art and are, in fact, widely used in industry. In a typical plasma spray operation an inert gas, such as argon, is electrically excited in a suitable spray gun resulting in a high temperature plasma. The plasma temperatures may be on the order of 20,000° F. and very high plasma velocities exiting the gun are possible.
Plasma spray coating procedures utilize the simple mechanism of injecting suitable coating powders in this hot, high velocity plasma stream wherein the particles are heated and propelled to the surface to be coated or where the deposit is to be formed. Because the particles are impacted at high temperature against the surface, dense adherent coatings may be achieved.
Plasma sprayed zirconia has found utility as a thermally insulative coating on certain gas turbine engine components. The typical zirconia spray powders in current use are stabilized with either calcia or magnesia, usually at about the 5 percent by weight stabilizer level. Basically, the stabilizer is used to generate and maintain the zirconia in a cubic metallographic structure for mechanical property reasons, including thermal shock resistance.
Unfortunately, although the calcia/magnesia stabilized zironcia may be readily sprayed and exhibits stability at lower temperatures, the stability of the composition at more elevated temperatures, as may be encountered in some gas turbine engine applications, is marginal.
It is also known that yttria will stabilize zirconia and will afford stability to higher temperature levels than either calcia or magnesia. However, spray trials with yttria stabilized zirconia soon reveal very low spray efficiencies with this composition, particularly in an interparticle bonding sense.
SUMMARY OF THE INVENTION
The present invention relates to plasma spray powders which consist primarily of yttria stabilized zirconia particles characterized by a very high spray efficiency. It contemplates plasma spray powders comprising a plurality of individual composite particles of yttria stabilized zirconia encased in a thin shell or coating of a high vapor pressure ceramic material, preferably calcia.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As previously described, the preferred plasma spray powders comprise yttria stabilized zirconia particles encased within a thin shell of calcia. The stabilizers are known to be effective in performing their function in zirconia when present in the order of a few mole percent. Yttria, for example, when present in an amount of 2-4 mole percent will stabilize zirconia. Calcia is the particularly preferred particle coating material since it, of course, is also an effective stabilizer.
Powder particle sizes vary depending upon the particular plasma spray equipment available and the experiences and preferences of the coating party. A typical powder particle size distribution, determined in accordance with ASTM B214, suitable for many plasma spray operations, is as follows:
______________________________________ % by weightSieve Min. Max.______________________________________+140 -- 1+200 -- 15+325 75 ---325 -- 25______________________________________ +indicates retained on sieve -indicates passing sieve
While the reasons for the excellent results with the powders of the present invention are not fully understood, calcia appears to exhibit three characteristics of importance thereto, viz., a relatively high vapor pressure, an ability to promote interparticle bonding, and inherently an ability to stabilize zirconia. Good interparticle bonding is essential not only to furnishing high spray efficiencies but also to the development of dense, adherent deposits. The high vapor pressure of calcia minimizes the risk of loss at the high spraying temperatures associated with plasma spray procedures. This apparently leads to retention of the thin calcia shell through the spraying operation and, concomitantly, permits the employment of a calcia shell of minimum thickness on the individual particles, thereby permitting the yttria to afford the primary stabilizing function. Finally calcia is compatible with the yttria/zirconia composition and does not act as an impurity therein but to the contrary, to the extent that it interacts with the yttria/zirconia, exhibits a beneficial stabilizing function of its own.
Following the unsatisfactory experience with the yttria stabilized zirconia powders without special treatment, a quantity of these powders were treated to form a thin calcia shell thereon. This was accomplished by first forming a deposit of calcium carbonate on the individual particles and converting the calcium carbonate to calcium oxide by the simple act of heating. Calcium carbonate can, as is known, be completely converted to calcium oxide at 600° C.
In the spraying of the calcia coated zirconia/yttria powders no special techniques were necessary. Plasma spray parameters are, of course, usually selected as a function of the equipment being used, the powders being sprayed, the substrate being coated, and the nature of the coating desired including its structure and thickness. These parameters are well recognized by those skilled in the plasma spray arts.
Trials with the powders of this invention have demonstrated that spray efficiencies of almost 100 percent are possible. Depending, of course, on the circumstances, the availability of the subject powders may provide other benefits as well. For example, the use of these powders may allow utilization of detuned or less carefully controlled spraying parameters. Further, particles of larger size, which might be used for example in the development of abradable deposits, may be sprayed because of the efficiencies possible.
Although the invention has been described in detail in connection with certain preferred embodiments and examples, certain modifications may occur to those skilled in the art within the true spirit and scope of the invention. | Fine powders comprising yttria stabilized zirconia powders encased in a thin calcia shell are provided for plasma spray coating processes. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. 13/382,926, filed Jan. 8, 2012, in the national phase of PCT Patent Application PCT/IB2010/053427, filed Jul. 28, 2010, which claims the benefit of U.S. Provisional Patent Application 61/231,025, filed Aug. 4, 2009, whose disclosure is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to data protection systems, and particularly to methods and systems for protecting mirrored data against disaster events using disaster-proof storage devices.
BACKGROUND OF THE INVENTION
[0003] Various methods and systems are known in the art for protecting data in computer systems against disasters such as earthquakes, storms, floods, fires and terrorist attacks. Some solutions involve replicating (mirroring) the data in a primary and a secondary storage device.
[0004] For example, PCT International Publication WO 2006/111958 A2, whose disclosure is incorporated herein by reference, describes a method and system for data protection that includes accepting data for storage from one or more data sources. The data is sent for storage in a primary storage device and in a secondary storage device. While awaiting an indication of successful storage of the data in the secondary storage device, a record associated with the data is temporarily stored in a disaster-proof storage unit adjacent to the primary storage device. When an event damaging at least some of the data in the primary storage device occurs, the data is reconstructed using the record stored in the disaster-proof storage unit and at least part of the data stored in the secondary storage device.
SUMMARY OF THE INVENTION
[0005] An embodiment of the present invention that is described herein provides a method for data protection, including:
[0006] monitoring a sequence of transactions that modify data in one or more volumes, wherein the transactions are transferred from one or more data sources to a primary storage in a given order and are replicated to a secondary storage, and wherein the one or more volumes belong to a volume group for which the transactions are guaranteed to be replicated to the secondary storage while retaining the given order;
[0007] periodically issuing artificial write transactions to a protection application field, which is predefined in a given volume belonging to the volume group, so as to insert the artificial write transactions into the sequence;
[0008] storing respective records indicative of the transactions of the sequence, including the artificial write transactions, in a disaster-proof storage unit, in order to enable reconstruction of at least part of the data of the volume group using at least a portion of the data that is replicated in the secondary storage device and at least some of the records that are stored in the disaster-proof storage unit upon occurrence of an event that affects data storage in the primary storage; and
[0009] upon verifying that a given artificial write transaction has been successfully replicated in the secondary storage, deleting from the disaster-proof storage unit the records corresponding to the given artificial write transaction and the transactions that precede the given artificial write transaction in the sequence.
[0010] In some embodiments, verifying that the given artificial write transaction has been successfully replicated includes periodically reading the artificial write transactions from the secondary storage. In an embodiment, periodically reading the artificial write transactions includes modifying a period of time between consecutive reading operations of the artificial write transactions in real time. In another embodiment, the volume group includes a consistency group.
[0011] In a disclosed embodiment, issuing the artificial write transactions includes assigning the artificial write transactions respective unique values. In an embodiment, the unique values include serial indices. In an alternative embodiment, the unique values include time stamps. In another embodiment, verifying that the given artificial write transaction has been successfully replicated includes reading a unique value of the given artificial write transaction, and verifying that the read unique value is different from a previously-read unique value. In yet another embodiment, periodically issuing the artificial write transactions includes modifying a period of time between consecutive artificial write transactions in real time. In still another embodiment, the protection application field is included in a dedicated protection application volume that belongs to the volume group.
[0012] There is additionally provided, in accordance with an embodiment of the present invention, a data protection apparatus, including:
[0013] an interface for monitoring a sequence of transactions that modify data in one or more volumes, wherein the transactions are transferred from one or more data sources to a primary storage in a given order and are replicated to a secondary storage, and wherein the one or more volumes belong to a volume group for which the transactions are guaranteed to be replicated to the secondary storage while retaining the given order; and
[0014] a processor, which is configured to periodically issue artificial write transactions to a protection application field that is predefined in a given volume belonging to the volume group so as to insert the artificial write transactions into the sequence, to store respective records indicative of the transactions of the sequence, including the artificial write transactions, in a disaster-proof storage unit, and to delete from the disaster-proof storage unit, upon verifying that a given artificial write transaction has been successfully replicated in the secondary storage, the records corresponding to the given artificial write transaction and the transactions that precede the given artificial write transaction in the sequence.
[0015] The present invention will be more fully understood from the following detailed description of the embodiments thereof, taken together with the drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a block diagram that schematically illustrates a data center, in accordance with an embodiment of the present invention;
[0017] FIG. 2 is a block diagram that schematically illustrates the operation of an embodiment of the present invention;
[0018] FIG. 3A and 3B are flowcharts that schematically illustrate a method for disaster-proof storage management, in accordance with an embodiment of the present invention; and
[0019] FIG. 4 is a timing diagram that schematically illustrates a method for data gap assessment, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS
Overview
[0020] Embodiments of the present invention provide improved methods and devices for protecting data through a disaster by storing it in a Disaster-Proof temporary Storage device (DPS). A typical environment in which the disclosed techniques are embodied comprises a system, where one or more Application Servers (ASs) issue transactions that modify data in one or more Primary Storage (PS) volumes through a Storage Area Network (SAN). A typical example of such a system is a Data Center (DC). The transactions may include writing data to the PS and/or deleting data from it. The PS comprises a group of one or more volumes, either virtual or physical, designated a “volume group”, which are mirrored in a Secondary Storage (SS) device. Typically, the PS is located in a local site and the SS is located in a remote site.
[0021] A volume group is characterized by a “sequence integrity” property, meaning that for any given sequence of transactions that are applied to the volume group, the order of transactions in the PS is guaranteed to be retained in the SS. A typical example of such a volume group is a Consistency Group (CG), wherein the volumes are managed as a single entity whose secondary images always remain in a consistent and restartable state with respect to their primary image and each other, up to a defined permissible time lag. The mirroring is performed by a Replication Appliance (RA) that is connected to the SAN and constantly sends a replica of the transactions that pertain to the CG over to the SS, typically over a Wide-Area Network (WAN).
[0022] A Protection Appliance (PA) simultaneously transfers the above transactions to a DPS that is located in the local site. Typically, the content of the DPS is organized in an indexed sequential access log. The sequential order of the transactions in the log reflects the order in which those transactions have been written to the PS, which is equal to the order of their writing to the SS, as stems from the sequence integrity property.
[0023] Later, should a disaster event occur that damages the operation of the DC, thus affecting the data storage in the PS, the DPS would transmit to the SS the most recent transactions that are stored in it and are assessed to be missing in the SS. The DPS uses for this transmission an Emergency Link (EL), which sometimes comprises several communication alternatives. The recovered transactions are then merged at the SS with the transactions that have been replicated to the SS prior to the disaster event, so that the secondary CG would exactly reflect the content of the primary CG prior to the disaster event.
[0024] The PA application software constantly determines the amount of recent transactions that shall be recovered should a disaster event occur. This determination is based on an assessment of the amount of transaction data that has been already written to the PS but its writing to the SS has not been confirmed yet. This amount is herein denoted Data Gap (DG). DG is comprised, at any given moment, of the transaction data that is accumulated in the RA buffers, and of a typically small amount of data that is accumulated within the PS-to-SS link. The latter data gap component is called in this disclosure “communication DG”. The DG is approximately equal to the difference between the CG transaction data that has been synchronously applied to the PS and its corresponding asynchronous replication within the SS. Embodiments of the present invention provide methods and systems for assessing DG with high accuracy.
[0025] In many cases the remote site is planned to serve as a backup DC for the local DC, should it fails to operate. Moreover, a reliable and instant application failover between the sites is sometimes desired. A necessary condition for a reliable failover is to avoid data discrepancy between the PS and the SS, hence, the assessed DG should not be smaller than the actual DG. In addition, for providing an instant failover, the assessed DG should be as close as possible to the actual DG in order to minimize the DG recovery time. This feature is advantageous, for example, when the EL comprises a narrow bandwidth link that includes an omni-directional wireless transmission from the DPS.
[0026] In a typical embodiment of the present invention, a new protection application volume, denoted V PA , is added to the CG in order to assess the DG. V PA instances in the PS and in the SS are denoted primary V PA and secondary V PA respectively. V PA comprises a protection application field, which is dedicated for the purpose of accurate DG assessment. A typical embodiment comprises creation of V PA through a configuration management of the data storage system. In some alternative embodiments, the PA creates the protection application field, either within one of the volumes that belong to the volume group or within a dedicated virtual volume that the PA creates.
[0027] The PA manages V PA as follows: It periodically issues artificial write transactions to the V PA so as to insert them into the transaction sequence that pertains to the CG. Each V PA related transaction contains a record, denoted R, to which the PA assigns a respective unique value. Each record that pertains to the series R is denoted herein R as well for the simplicity. Each new record that is written to V PA updates the V PA protection application field, hence this field always reflects the last R unique value that the PA wrote to V PA . The inter-record period of R (i.e., the time interval between writing successive records R) is denoted Tw. R is written and stored within the DPS, as well as within the SS, in the same manner as the data of the other volumes that pertain to the CG.
[0028] In addition to the above writing process of R, the PA also manages a reading process wherein it constantly reads the content of the secondary V PA , i.e., the last R unique value that was written in the SS. Reading a new R value from the SS constitutes a confirmation for the PA that this R, as well as all the transactions that pertain to the CG and precede that R, have been already written successfully to the SS. This confirmation stems from the sequence integrity property of the CG. Consequently, the PA would delete the corresponding R from the DPS log, together with the log stored transactions that preceded it, since those transactions will not be needed for recovery. This deletion procedure limits the DPS content size to the real DG size plus an assessment error. The maximal assessment error is approximately equal to the amount of data that is written to the PS during Tw+Trt, where Trt denotes the round trip delay toward the SS. As Tw may be set as small as Trt the assessment error is approximately equal to the communication DG size.
[0029] In addition to the achieved DG assessment accuracy, the above method is a RA-independent mechanism, and therefore allows for an easy integration of a DG management and recovery system that comprises a PA and a DPS, as described above, in a DC that already comprises a mirroring system.
[0030] Embodiments of the present invention are in no way limited to data centers, and may be used in other environments, e.g. in data acquisition sites and in surveillance centers. The disclosed techniques are also applicable to storage volumes that are not necessarily arranged as CG, e.g. wherein there is no dependency between the transactions that pertain to the different volumes in the group, provided that the transaction ordering in the PS is always retained in the SS.
System Description
[0031] FIG. 1 is a block diagram that schematically illustrates a data storage system 100 , in accordance with an embodiment of the present invention. System 100 comprises a local site 101 and a remote site 102 , which are interconnected by a WAN 103 . The illustrated WAN represents any communication means that can be used, in different example embodiments, to interconnect the above sites, e.g., an Internet Protocol (IP) network, a point to point link or a Fibre Channel based network. Local site 101 comprises a Data Center (DC) wherein one or more Application Servers (ASs) 104 issue transactions to one or more Primary Storage (PS) devices 112 . Storage Area Network (SAN) 108 transfers the transactions to the storage. SAN 108 comprises, in typical embodiments of the present invention, one or more Fibre Channel switches. In alternative example embodiments, the SAN may be based on Internet Small Computer System Interface (iSCSI). Yet in other embodiments SAN 108 may represent the attachment of one or more Network Attached Storage (NAS) devices to ASs 104 .
[0032] PS 112 typically comprises one or more volumes, either virtual or physical, that are arranged as a Consistency Group (CG). The CG is mirrored to a Secondary Storage (SS) 114 that is located at remote site 102 . The mirroring is performed by a Replication Appliance (RA) 116 that is connected to SAN 108 and constantly sends a replica of all the transactions that pertain to the CG, over WAN 103 , to a counterpart replication appliance RA 124 . In some embodiments, specific replication software agents within ASs 104 generate the transactions' replica and transfer it to RA 116 through SAN 108 . In alternative embodiments SAN 108 is configured to generate this replica and to provide it to RA 116 through a dedicated port. In further alternative embodiments RA 116 is not resorted to and ASs 104 communicate with remote site 102 directly. In further alternative embodiments, the replication is performed directly from PS 112 to SS 114 .
[0033] Remote RA 124 is typically configured to extend the transactions coming from RA 116 over a remote SAN 128 , which transfers the transactions to SS 114 . A Protection Appliance (PA) 140 simultaneously receives yet another replica of the CG related transactions. PA 140 comprises an interface 141 for communicating with SAN 108 . PA 140 also comprises a processor 142 which executes the logical operations of the PA. PA 140 directly transfers the above transactions to a Disaster-Proof Storage device (DPS) 144 . In an alternative embodiment, PA 140 communicates with DPS 144 via SAN 108 and interface 141 . The DPS is configured to store the transactions that PA 140 writes to it in a log that is organized in indexed sequential access manner. The sequential order of the transactions in the log reflects the order in which those transactions have been written to PS 112 , which is equal to the order of their writing to SS 114 , as stems from the sequence integrity property of CGs.
[0034] DPS 144 is configured to sense a major failure of local site 101 , which may happen through a disaster event and would affect the data storage in the PS. Should such failure occur DPS 144 would transmit to SS 114 the most recent transactions that are stored in it and are assessed to be missing in the SS. DPS 144 uses for this transmission an Emergency Link (EL) 148 , which typically comprises several communication alternatives. In typical embodiments, one of these alternatives would be an omni-directional wireless transmission. EL 148 passes the recovered transactions to a counterpart PA 152 at the remote site, which applies them to SS 114 through SAN 128 , either directly or via RA 124 . The recovered transactions complement the transactions that were replicated to the SS prior to the disaster event, so that the secondary CG would exactly reflect the content of the primary CG prior to the disaster event.
[0035] In some embodiments, the remote site comprises another DPS 156 , e.g., when site 102 operates as an active DC that comprises optional ASs 136 , such that storage 112 serves as a mirroring medium for storage 114 . Should the DC in site 102 fail due to a disaster event, DPS 156 would recover the transactions to storage 114 that are missing in storage 112 through an EL 160 .
[0036] The configuration of system 100 shown in FIG. 1 is an example configuration, which is chosen purely for the sake of conceptual clarity. PS 112 and SS 114 may comprise any suitable type of storage device, such as magnetic disks or solid-state memory units. System elements that are not mandatory for understanding the disclosed techniques were omitted from the figure for the sake of clarity. In alternative embodiments, other system configurations can also be used. For example, RA 116 may write to SS 114 via WAN 103 and SAN 128 , without the mediation of RA 124 . In other alternative embodiments PS 112 may comprise multiple CGs that may be mirrored to SS 114 or to multiple remote sites.
[0037] In some embodiments, the functions of PA 140 are implemented in software running on a suitable processor. In alternative embodiments, some or all of the functions of PA 140 can be implemented in hardware, or using a combination of hardware and software elements. In some embodiments, PA 140 comprises a general-purpose computer, which is programmed in software to carry out the functions described herein. The software may be downloaded to the computer in electronic form, over a network, for example, or it may, alternatively or additionally, be provided and/or stored on non-transitory tangible media, such as magnetic, optical, or electronic memory. Further aspects regarding the operation of PA 140 , and data storage using disaster-proof storage devices in general, are addressed in PCT International Publication WO 2006/111958, cited above.
Logical System Operation
[0038] FIG. 2 is a block diagram that schematically illustrates the operation principles of an embodiment of the present invention. A group of virtual volumes V 1-1 , V 2-1 , . . . V k-1 and V PA-1 212 constitutes a CG whose primary instance is denoted CG 204 and is stored in PS 112 . RA 116 constantly replicates CG 204 to remote site 102 through WAN 103 . Within the remote site, RA 124 receives the replicated transactions that pertain to the CG and copies them to virtual volumes V 1-2 , V 2-2 , . . . V k-2 and V PA-2 216 respectively, thus forming a mirrored CG 208 in SS 114 . V PA , which is the general notation of V PA-1 and V PA-2 , comprises a single record, which PA 140 manages as follows:
[0039] PA 140 generates a periodical series of serially indexed records, denoted R 218 , and writes it in a series of transactions W PA 220 to V PA-1 212 . For the sake of simplicity, R 218 denotes the series of records as well as each separate record that pertains to this series. The main content of record R is its running index. As V PA comprises a single record, each new W PA 220 tramples the previously stored one. Immediately after writing W PA 220 to V PA-1 212 , PA 140 receives a replica of W PA 220 , as explained above, and writes it as W PA 224 to DPS 144 . RA 116 receives a replica of W PA 220 as well, and combines it as W PA 228 within a transaction sequence . . . W-n, W-n+1, . . . W PA , . . . W 0 that it replicates to remote site 102 over WAN 103 . In this sequence, all the transactions that have been written to CG 204 prior to W PA 228 will be replicated to CG 208 prior to W PA 228 as well, as stems from the sequence integrity property of CGs. RA 124 receives the above record sequence and copies it to CG 208 . In particularly it writes W PA 232 record series to V PA-2 within CG 208 .
[0040] PA 140 also manages, within DPS 144 , a sequential list 234 that contains the R records that it has recently written to the DPS. Each list 234 entry contains also a pointer to the corresponding R record in the log.
[0041] Concurrently with the above writing process of W PA , PA 140 is configured to constantly read, typically over WAN 103 , the content of V PA-2 216 , in a read transaction R PA 236 . PA 140 receives R PA 236 through the WAN as R PA 240 and checks its index. Upon reading a new R PA index, PA 140 deletes the following data that is stored in DPS 144 : The corresponding entry in list 234 , the W PA entry that it has pointed in the log and all the log entries that have preceded that W PA . PA 140 can safely delete the above data due to the fact that replication of that data to CG 208 has been actually confirmed by the above new R PA index.
[0042] The deletion would leave in DPS 144 only the necessary transactions for recovery, should a disaster event occur, thus shortening later recovery time through EL 148 . This amount of transactions is an assessment of the difference, at any given moment, between CG 204 and CG 208 , which is called “Data Gap” (DG). In alternative embodiments, DPS 144 is arranged to manage list 234 and the above deletion process according to information regarding new R PA 240 indices, which PA 140 constantly conveys to DPS 144 .
DG Assessment Method
[0043] FIG. 3A is a flowchart that schematically illustrates the writing part of a method for DG assessment and for managing DPS 144 content, in accordance with an embodiment of the present invention. The method begins by adding a virtual volume V PA to a consistency group CG, at an adding V PA step 304 . This adding step demonstrates an option to integrate the disclosed techniques into an existing DC. In other embodiments of the present invention, wherein a mirrored CG comprises V PA when it is established, step 304 may be redundant. In a W PA writing step 308 , PA 140 writes a serially indexed record R in transaction W PA 220 to V PA-1 212 . DPS 144 receives a replica of W PA 220 , denoted W PA 224 . RA 124 writes a second replica of W PA 220 , denoted W PA 232 , to secondary V PA-2 216 . In a wait Tw step 312 , PA 140 waits a period Tw 314 and resumes step 308 , thus forming a series of transactions W PA .
[0044] FIG. 3B is a flowchart that schematically illustrates the reading part of a method for DG assessment and for managing DPS 144 content, in accordance with an embodiment of the present invention. This part of the method begins with a read R PA 316 step, wherein local PA 140 issues a read transaction, denoted R PA , for checking the actual V PA-2 index at remote CG 208 . PA 140 waits for the arrival of the read index in a wait Trt step 324 , wherein Trt denotes the round trip delay of the R PA read transaction. PA 140 is configured to make the following decision, in a decision step 328 , according the received R PA index: If the index value has not been changed relative to the previous read index then PA 140 would resume step 316 . If the index value is a new one, then PA 140 assumes a deletion step 332 . In deletion step 332 PA 140 deletes all DPS 144 log transactions that precede the stored W PA , whose index is the same as the newly read index, including that W PA . PA 140 resumes step 316 after the deletion.
[0045] FIG. 4 is a timing diagram that schematically illustrates a method for DG assessment, in accordance with an embodiment of the present invention. A time axis 404 illustrates V PA related events that occur over time in PA 140 . PA 140 issues transactions W PA1 , W PA2 , . . . to VA PA-2 216 with inter-transaction period Tw 314 . Tw 314 is set as twice the value of the round trip delay toward SS 114 , denoted Trt 324 . In alternative embodiments, Tw may be set as small as Trt for minimizing the DG assessment error to the communication DG size over the WAN. PA 140 concurrently issues read transactions from V PA-2 216 with inter-transaction period Trt 314 .
[0046] In FIG. 4 those transactions are illustrated in terms of the actual V PA-2 record indices that PA 140 reads. These indices are denoted R 0 , R 1 , . . . R 4 on a time axis 408 . PA 140 receives each read index Trt seconds after the issuance of the read transaction. The read indices are denoted on time axis 404 , wherein indices that are not new are omitted. In alternative embodiments, PA 140 software identifies the W PA records with timestamps instead of running indices.
[0047] PA 140 managing the transaction log within DPS 144 is exemplified in the following example: PA 140 issues in a time t w3 412 a transaction W PA3 . PA 140 receives W PA3 's index R 3 the first time at a time instance t R3 416 . PA 140 then deletes all the transactions that have been stored in DPS 144 log before W PA3 , including W PA3 itself. This deletion action is illustrated in FIG. 4 by a double arrow 420 . In alternative embodiments, indices R 3 are substituted by time stamps or using any other suitable type of unique values that assigned to the artificial write transactions. Yet in other alternative embodiments, the read transaction period is adjusted to be larger than Trt in order to save overhead throughput over WAN 103 . On the other hand, the inter-transaction periods of W PA 220 and R PA 236 are typically limited in order to minimize the DG assessment error.
[0048] In further alternative embodiments, PA 140 adjusts, in real time, the W PA 220 and R PA 236 inter-transaction periods as follows: The PA limits the overall W PA and R PA throughput so as to ensure a minimal impact on the actual replication throughput through WAN 103 . In addition, the PA limits Tw 314 magnitude so that at any given moment the actual total writing amount to CG 204 during Tw would be much smaller than the overall content size within DPS 144 . Yet in further alternative embodiments of the present invention PA 140 may set, either in software or in hardware or in a combination thereof, any other suitable combination of W PA 220 and R PA 236 inter-transaction periods. These combinations may rely on predetermined values of relevant factors like Trt, overall writing throughput to CG 204 and the effective throughput through WAN 103 . These values may alternatively be determined in real time, and affect the chosen combination accordingly.
[0049] Although in the embodiments described herein the DG assessment and DPS management mechanism is implemented externally to RAs 116 and 124 , they can alternatively be implemented within the RAs thus saving separate PAs 140 and 152 .
[0050] It will thus be appreciated that the embodiments described above are cited by way of example, and that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, the scope of the present invention includes both combinations and sub-combinations of the various features described hereinabove, as well as variations and modifications thereof which would occur to persons skilled in the art upon reading the foregoing description and which are not disclosed in the prior art. | A method includes monitoring a sequence of transactions in one or more volumes. The transactions are transferred to a primary storage ( 112 ) in a given order, and are replicated to a secondary storage ( 114 ). The volumes belong to a volume group ( 204 ) for which the transactions are guaranteed to be replicated while retaining the given order. Artificial write transactions ( 228 ) are periodically issued to a protection application field, which is predefined in a given volume ( 212 ) belonging to the volume group. Records indicative of the transactions, including the artificial transactions, are stored in a disaster-proof storage unit ( 144 ). Upon verifying that a given artificial transaction has been successfully replicated in the secondary storage, the records corresponding to the given artificial write transaction and the transactions that precede it in the sequence are deleted from the disaster-proof storage unit. | 6 |
CROSS-REFERENCE TO RELATED DOCUMENTS
[0001] The present invention is a continuation-in-part (CIP) to patent application Ser. No. 09/654,320 entitled “Method and Apparatus for Multifaceted Profiling of Individual Cobrand Users” filed on Sep. 01, 2000, disclosure of which is incorporated herein in its entirety herein by reference.
FIELD OF THE INVENTION
[0002] The present invention is in the field of Internet-based services and applications, and pertains more particularly to methods for generating a concise data package containing target information about a user for the purpose of directing ad generation to an interface employed by the user.
BACKGROUND OF THE INVENTION
[0003] The information network known as the world-wide-web (WWW), which is a subset of the well-known Internet, is arguably the most complete source of publicly accessible information available. Anyone with a suitable Internet appliance such as a personal computer with a standard Internet connection may access (go on-line) and navigate to information pages (termed web pages) stored on Internet-connected servers for the purpose of gathering information and initiating transactions with hosts of such servers and pages.
[0004] Often times, in order to improve the quality of services offered by a particular website, it is important to understand user activity in relationship to that site. This is to say that while a user is navigating through a website, obtaining a dynamic profile of the user's habits, activities and personal information would prove beneficial to the overall improvement of a service providing or commercial website. In addition to utilizing user profiles for website service-enhancement purposes, companies routinely pay for such information in order to better target users for advertising and marketing purposes.
[0005] In a cobrand relationship known to the inventor, cobrand partners contract with a service-providing entity in order to provide Internet services offered by the entity. The cobranded services are made available to subscribers of the cobrand partners through dedicated servers maintained by the service-providing entity. Users who subscribe to such services typically have at least some personal profile information known to the cobrand partners through their normal subscription and interaction activities. In addition, a service-providing entity may track certain information about users who are accessing and interacting with cobranded services maintained by the service-providing entity. For example, information such as types of products purchased, types of web pages accessed at service sites, frequency of buying, time spent at sites, and so on, may be tracked and stored in a secure database by the service-providing entity. This is made possible by the fact that the service-providing entity maintains and provides the services and the equipment through which the services are made available.
[0006] There are a variety of known methods for obtaining information about individual users who visit websites online. Some commonly known methods are sending and retrieving interactive cookies, conducting on-line surveys, parsing completed online forms, recording purchase histories, and many other techniques. A typical user profile automatically compiled by a Web company is limited to information that can be obtained from the user while at one of the company-sponsored sites, or through interacting with the user during registration processes. As such, the profile is not complete or well rounded and tends to reflect content related to the nature of business conducted by the Web company. For example, a purchase history compiled by a Web-based clothing retailer is limited to the subject of clothing. In order to obtain a well-rounded profile of an individual that covers a variety of topics, information must be bought, sold, or traded between Web companies doing business on the Internet. It is known in the art that there are many companies in existence that specialize in information brokering. In the case of cobranding, where the service-providing entity provides proxy navigation and data summary services for users, data about a user's activity related to interaction with cobrand services includes data related to a plurality of disparate Web-sites, which are involved in some aspect of the cobrand services. It has occurred to the inventor that much information may be automatically obtained about users from user interaction and proxy interaction with many Web sites without being required to obtain the data through purchase or trade with companies hosting Web-sites involved in cobranded services.
[0007] A system known to the inventor and taught in the related document listed in the cross-reference enables automated collection of data about a user through monitoring user interaction on the network. The data-collection system includes a proxy server connected to the data-packet-network for providing proxy services and for monitoring user access and interaction with those services, a dedicated server interface connected to the network for providing user access to the proxy services, and a software application running on the proxy server for collecting and storing data obtained as a result of active user-interaction with the proxy services. In preferred embodiments of the invention, the data is collected in an automated fashion and is used for the construction of multifaceted user profiles, which may be periodically updated in an automated fashion as a result of continued user interaction with provided proxy services through the dedicated server interface.
[0008] The system also incorporates manual techniques used in data collection and integrates results obtained manually with those obtained in an automated fashion to compile detailed profiles of individual users. One of the uses of a complete and detailed profile on a user is to incorporate the compiled information for use in advertising as is generally known in the art. However, in an automated network environment ads must be delivered into user-operated interfaces as accessed web pages are loaded. In current art, ads delivered according to profiling, either text or graphic, are more or less static in that they do not change in content to the extent that a user may change in personal habits, preferences, or other profiled attributes. These ads are decided on based on an overall picture of a user or a group of users. Therefore, they are not really as flexible or target-oriented as might be desired by both users and advertising companies.
[0009] It has occurred to the inventors that through further innovation and refinement, an automated profiling system may be adapted to define a user's profile in such a way as to incorporate slight changes in content, categories, and preferences as they are discovered. However, in order to cause ads to be delivered such that they incorporate evolving changes, a system must be developed to communicate the mean of those changes in a way that may be utilized on the fly as Web pages delivered into a user interface are loaded.
[0010] What is clearly needed is a system for packaging and communicating profile data to ad sources such that dynamic ads may be selected and delivered based on mean changes in the profile data. Such a system would provide a much greater degree of compliance of delivered ads to a user's preferences and status states enabling a greater hit rate and a greater profit margin for ad companies.
SUMMARY OF THE INVENTION
[0011] In a preferred embodiment of the present invention, an advertisement selection and delivery system for selecting advertisements based on profile information and rendering the advertisements as accessible to a user operating a network-capable appliance connected to a data-packet-network is provided. The system comprises, a first server node connected to the network, the first server node functioning as a user access point on the network, a mass storage repository accessible to the first server node, the repository for storing and serving user profile data, a second server node connected to the network, the second server node for generating user preference data, at least one advertisement server connected to the network, the advertisement server for serving advertisement data, a software application for generating user preference lists and performing advertisement selection, and at least one network-capable appliance connected to the network the network-capable appliance for receiving the advertisement data.
[0012] In a preferred use, a user operating the network-capable appliance accesses the first server node and receives the advertisement data, the advertisement data selected for service by matching the user preference data to stored advertisements, which are rendered accessible to the user during the time of user access to the system from the network-capable appliance.
[0013] In a preferred embodiment, the system is implemented on the Internet network. In addition to being connected to the Internet, the first server node and the second server node are, in one embodiment, connected to each other by a separate dedicated network. The software application is, in one implementation, distributed in part on the second server node and in part on the at least one advertisement server. In this aspect, the part of the software application executing on a second server node directs generation of user preference lists and the part of the software application executing on the at least one advertisement server performs the advertisement selection according to a user preference list obtained from the second server.
[0014] In another aspect, the software application resides in whole and executes on the second server node and advertisement selection is performed by the second server node using advertisements delivered thereto from the at least one advertisement server. In this aspect, the second server node also serves the selected advertisements, functioning as an ad broker. Also in some aspects, the first server node is a cobranded server node servicing clients of a cobrand partner of the entity hosting the system. In this aspect, the advertisements may include e-mail messages or instant messages. However, in preferred aspects, the advertisements served are banner and text advertisements.
[0015] In one aspect, the network-capable appliance accesses the system through a wireless network. In another aspect of the system, the preference lists are generated using a knowledge base data system. In still another aspect, the preference lists are used as search criteria in conjunction with a search engine.
[0016] In another aspect of the present invention, a preference-data generation server for generating preference data using data mined from user profile data is provided. The server comprises, a data port for receiving user profile data, a data port for accessing a knowledge database and a software application for mining the user profile data and for generating preference summaries by equating the mined profile data to pre-established preference categories listed in the knowledge database. In all aspects, the preference summaries are generated in the form of categorized and prioritized data lists.
[0017] In one embodiment, the preference-data generation server further comprises, a data port for receiving pre-configured advertisement data, a data port for serving advertisement data and a software application for matching the advertisement data to individual ones of generated data lists and for selecting the advertisement data most closely matching the generated data lists for service. In a preferred aspect, the matching advertisement data is served to a network-access point established on a data-packet-network, which, in preferred instances, is the Internet network. The preference-data generation server, in one aspect, further comprises a data port for serving the prioritized data lists. In this aspect, the prioritized data lists are served to at least one advertisement server operating on a data-packet-network, which is the Internet network. Also in this aspect, the process of selecting advertisements is performed by the at least one advertisement server.
[0018] In another aspect of the present invention, a method for dynamically serving advertisement data based on user profile information to a user interface maintained on a data-packet-network is provided. The method comprises the steps of, (a) compiling and storing the user profile information on an ongoing basis, (b) accessing the user profile information in order to mine the information, (c) mining the accessed user profile information for preference data, (d) formulating the preference data into a concise summary-data list, (e) selecting pre-configured advertisements from a database containing stored advertisements, the selection accomplished by matching the advertisements to data contained in the summary-data list and (f) serving the selected advertisements to the user interface.
[0019] In a preferred embodiment, the method is practiced on the Internet network. In a preferred aspect of the method in step (a), compilation of user profile information is accomplished by recording user activity on the network. In another aspect, in step (a), compilation of user profile information is augmented through manual data procurement methods. In a preferred aspect of the method, steps (b)-(f) are performed as a sequence launched as a result of the profiled user connecting to and accessing the user interface using a network-capable appliance.
[0020] Further to the above, in step (c), data mining is accomplished through a parsing method. Also, in step (c), the preference data is, in preferred embodiments, categorized and prioritized according to preconfigured preference categories related to types of advertisements. In one aspect of the method, in step (d), the summary-data list is of the form that can be propagated through the network. In this aspect, in step (d), the summary-data list is sent to an advertisement server wherein the advertisement server performs steps (e) and (f). In still another aspect, steps (c)-(f) are accomplished by a single server node connected to the network. In one aspect of the method in step (e), the advertisements are generated to fit the summary-data list and are of the form of instant messages advertisements. In another aspect, in step (e), the advertisements are generated to fit the summary-data list and are in the form of emailed advertisements.
[0021] Now, for the first time, a system for packaging and communicating profile data to ad sources such that dynamic ads may be selected and delivered based on mean changes in the profile data is provided. Such a system provides a much greater degree of compliance of delivered ads to a user's preferences and status states enabling a greater hit rate and a greater profit margin for ad companies.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0022] [0022]FIG. 1 is an overview of a communication network wherein cobrand user-profiling is practiced according to an embodiment of the present invention.
[0023] [0023]FIG. 2 is a block-diagram illustrating various data categories and data-gathering methods used to create a multifaceted user-profile according to an embodiment of the present invention.
[0024] [0024]FIG. 3 is an overview of a communication network wherein target advertisement based on evolutionary profiling is practiced according to an embodiment of the present invention.
[0025] [0025]FIG. 4 is a process-flow diagram illustrating various steps for profiling and ad serving based on received profile information according to an embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] [0026]FIG. 1 is an overview of a communication network 9 wherein cobrand-user profiling is practiced according to an embodiment of the present invention. Communication network 9 contains all of the equipment and network connections required in order to establish a functional network-communication capability.
[0027] In a preferred embodiment of the present invention, communication network 9 is implemented on the Internet network, which is represented herein by an Internet backbone 11 . Internet backbone 11 represents all of the lines, connection points, and equipment that make up the Internet network as a whole. Therefore, there is no geographic limit to the practice of the present invention.
[0028] A plurality of cobrand servers (CBS) 23 , 25 , and 27 are illustrated, in this example, as connected to Internet backbone 11 . CBS 23 - 27 are adapted as Internet file servers dedicated to users of cobrand services provided by a service-providing company, which also maintains the servers. A main server 15 , also illustrated as connected to Internet backbone 11 , is adapted as a data-aggregation and distribution source and is hosted by the same service provider hosting servers 23 - 27 . Cobrand servers 23 - 27 are dedicated to cobrand partners and their subscribers whom have elected to access services offered by the service provider, which hosts server 15 .
[0029] In addition to data-aggregation and distribution services (cobrand service) server 15 also functions, in this example, as an activity-tracking server tracking on-line activity of cobrand users. Companies providing cobrand services to their subscriber-ship typically specialize in providing search capabilities and limited portal services. The companies hosting CBS 23 - 27 may be termed cobrand partners of the described service-providing company. The nature of services provided by CBS 23 - 27 will depend on the nature of agreements forged between various cobrand partners and the service-providing entity. For example, some of CBS 23 - 27 may allow users to obtain e-mail from various e-mail servers. Likewise, each of CBS 23 - 27 may provide varying functionalities generally related to data collection, aggregation and summary services. It is sufficient to say that subscribers to cobranded services interface with CBS 23 - 27 in order to receive such services.
[0030] A plurality of content servers (CS) 19 and 21 are adapted as Internet data servers hosted by companies contracted to provide specific content to the service-providing entity, which makes the content available through CBS 23 - 27 . Servers 19 and 21 are illustrated herein as connected to Internet backbone 11 .
[0031] CS 19 and 21 are dedicated to providing specific Web content such as weather information, stock quotes, financial news, entertainment news, and so on. There are many possibilities as to the nature of the content provided by servers 19 and 21 . In some cases content provided by servers 19 and 21 may be inaccessible without subscription or membership. It is noted herein that CS 19 and 21 are not, in this example, hosted by the entity hosting main server 15 and cobrand servers 23 - 27 rather, they are hosted by companies contracting with the service-providing entity of this example and provide content according to contract stipulation.
[0032] A plurality of Free (FS) content servers 29 and 31 are illustrated herein as connected to Internet backbone 11 . FS 29 and 31 , located to the right of CBS 23 - 27 , in this example, and are also adapted as Internet data servers, but in this case are not providing content to CBS 23 - 27 . FS 29 - 31 are not in any way associated with the entity hosting main server 15 , however, in some cases may be accessed through main server 15 by proxy such that accessed content may also be tracked by main server 15 . Like CS 19 - 21 , there are many possibilities as to the nature of content provided by FS 29 - 3 1 , the term “free” is used in this example to convey that the services and/or content provided within FS 29 - 31 is available to anyone who accesses it.
[0033] It will be apparent to one with skill in the art that there may be many more CBS, CS, and FS illustrated in this example without departing from the spirit and scope of the present invention. The inventor illustrates only a few of each class of server in this example and deems the illustration sufficient for explanation of the present invention. It is repeated here that CBS 23 - 27 are cobrand servers maintained by a service-providing entity also hosting main server 15 . CS 19 - 21 are content servers hosted by companies contracting with the described service-providing entity to make their content available to CBS 23 - 27 . FS 29 - 31 are free servers not affiliated in any way with the service-providing entity.
[0034] A plurality of cobrand subscribers/users 17 (within dotted rectangle) is illustrated as having Internet connection to Internet backbone 11 . Internet connection in this example includes all of the known methods for accessing the Internet network. An internet-service-provider (ISP) is not detailed in this example, but may be assumed to be present in a scenario where users 17 are accessing Internet 11 through normal dial-up modem technology, which is most common. Other methods include wireless modem connection, cable modem connection, and so on.
[0035] In this example, users 17 are illustrated as operating personal computers (PC) to access Internet 11 . In actual practice, any Internet-capable appliance may be used to practice the present invention as long as it has network-browsing and display capabilities. Each user 17 may freely navigate to and interact with CBS 23 - 27 , FS 29 - 30 , or CS 19 - 21 . However, when users are accessing cobrand services from one of CBS 23 - 27 , at least part of the service enables them to have data obtained from any of CS 19 - 21 or FS 29 - 31 . For example, if a user 17 is logged into CBS 27 to receive cobrand services, specific data requested by the user such as weather or financial news would be obtained by proxy from CS 19 - 21 because of contract stipulation. If data is requested from any of FS 29 - 31 , then the requesting user must provide information such as a URL address and type of data required to enable proxy data collection and presentation because there is no affiliation between FS 29 - 31 and CBS 27 .
[0036] Main server 15 , as previously described, can log the activities of each of users 17 when they are interacting with CBS 23 - 27 . Furthermore, server 15 has the ability to record activity information related to any proxy data request involving any other servers navigated to on behalf of users 17 . As a result, much data specific to a user's activity may be obtained without giving notice to or requesting data from companies hosting servers 19 - 21 or servers 29 - 31 .
[0037] An instance of software (SW) is provided to execute on main server 15 . SW at server 15 is adapted to record any user-activity data routed through server 15 . Therefore, data obtained through cobrand services offered by CB 23 - 27 may be logged and identified to particular users, and mined for data to include as profile data. Server 15 may record types of content requested, description and class of items purchased, nature and description of Web-sites targeted for data requests, frequency of same type requests, lists containing URLs and descriptions of user-registered Web sites, and so on. Data about a cobrand user's on-line activity and behavior is compiled and organized within server 15 and then stored as a part of that user's multifaceted profile.
[0038] Other information about users may be obtained from companies hosting CBS 23 - 27 . Such information may include personal information related to subscription and registration to receive cobrand services, information obtained through registration and interaction with a cobrand partners regular services routinely accessed by cobrand users, and so on. In this way, much of a multifaceted profile can be automatically generated and stored for cobrand users 17 . If a user is a frequent cobrand user and is particularly prolific with on-line activity, then many facets about that user's activity and behavior may be learned and recorded. Profiling a user in this manner greatly reduces the need for trading or purchasing partial profiles compiled by a plurality of un-related sources. However, a multifaceted profile may, of course be enhanced by supplementing the profile with purchased or traded data originating from out-side sources.
[0039] Significant market advantages exist for an entity that can obtain a multifaceted profile on each of its clients. For example, many user profiles may be mined for more specific data, which may be generated into list-reports detailing preferences and activity traits of many users. Such lists may be created and tailored for advertisement companies or other service providers willing to pay for the information. Thresholds and special rules may also be implemented during profile configuration and maintenance such that profile information may be automatically updated over prolonged user patronage of cobrand services.
[0040] [0040]FIG. 2 is a block-diagram illustrating various data categories and data gathering methods used to create a multifaceted user-profile according to an embodiment of the present invention. In this example, there are three basic categories of data used to create a dynamic multifaceted profile. These categories are illustrated in this example, by element number 37 (demographic info), element number 39 (account info), and element number 41 (on-line behavior). Element number 43 represents various data-gathering methods, which may be used to obtain data described in the data categories mentioned above.
[0041] Every cobrand user is supplied with a cobrand identification (ID) and a member ID. In this way, data obtained and warehoused from internal or external sources is easily identifiable to a particular user. Profiles may be automatically assembled using this warehoused data according to enterprise rules. It is important to note herein that each data category 37 , 39 , and 41 may be populated using automatic data-gathering methods (element 43 ) such as data capture during interactive sessions. Data capture, as is used in this specification, means recording any and all data about a user during an on-line session, which includes any proxy services. Of course, some data may be supplied by purchasing from the outside, trading, or sharing with partners. These additional options are included under data-gathering methods 43 . For the most part however, automated data capture should be sufficient for supplying a viable multifaceted profile in most cases. This is especially true if a user is prolific in his or her patronage of cobranded services.
[0042] Referring now to demographic info 37 , there is illustrated a plurality of subcategories, which will be discussed from top to bottom. Income level is one important subcategory of demographic information. By knowing a user's income level, advertisements for travel, financial services, and consumables may be more properly tailored for the individual. Location information may also be used to enhance local advertising.
[0043] Family relationships are important for understanding lifestyle characteristics, identifying future consumers, and so on. Gender, age, and income levels of family members may also be important in creating a multifaceted profile. Hobbies and other preferences may also be included in data gathered for demographic information. Such data also contributes to understanding lifestyle characteristics and identifying products and services that may fit a user.
[0044] Demographic information may be obtained through recording on-line purchase events, registration events, and from general population of on-line forms. Therefore, most demographic information may be obtained through automated data-capturing techniques. In some cases, companies contracting for cobrand service-enhancement with a service-providing entity may simply forward or share some demographic information. Such an arrangement may be, in some embodiments, required as part of contract negotiation. In other cases, especially if certain users are not prolific in on-line activity, demographic information may be purchased from the outside or obtained through trade with outside organizations. Therefore, information that cannot be obtained through data capture may be obtained through other methods in order to supplement any relatively weak profiles.
[0045] Account information 39 is illustrated herein as divided into 4 basic subcategories. These subcategories are listed from top to bottom as entertainment, business, financial, and investment. Each category may be further divided into more subcategories has deemed appropriate. Account information represents data obtained from on-line accounts belonging to a particular user. A user may subscribe to many of these accounts and may add them to cobrand service sites for the purpose of being able to access information from such accounts without physically navigating to them. As proxy services are performed on behalf of a user concerning a user's registered accounts, data used in accessing the accounts and data returned as a result of task performance is collected and incorporated as profile data.
[0046] As data is automatically compiled about a user over time, the user's profile becomes more and more valuable and accurate. After a period of time, the service-providing entity maintaining the cobrand services and the user's profile may generate automated reports detailing certain aspects of the user's profile for selective distribution to paying clients. Secure information such as credit card numbers, Social Security numbers, personal identification numbers, passwords, and the like remain in a state of data encryption, or otherwise deleted from data reports containing profile information.
[0047] On-line behavior is compiled using user-activity and server-activity data. Such raw data is collected and analyzed in order to compile an on-line behavior profile. Subcategories of user activity that may constitute on-line behavior illustrated within block 41 are listed and discussed from top to bottom.
[0048] Identification of Web sites visited either directly or through proxy services maybe automatically captured. Types of products purchased from those sites may also be automatically captured as well as frequency parameters associated with purchases illustrated herein as a subcategory of products purchased. Frequency of purchases may simply mean how often a purchase is made over a number of visited sites. The frequency of purchases may also mean the frequency of purchase of one particular product.
[0049] Time accessing cobrand services may also be included and incorporated in forming an on-line behavior profile. Parameters surrounding banner-ad or sponsor clicking may be incorporated in order to determine certain preferences. Finally, on-line histories may be created and maintained on virtually any category or subcategory associated with blocks 39 and 41 .
[0050] In a preferred embodiment of the present invention, most if not all of the data compiled about a user is collected using automated data capturing techniques implemented during the normal course of the user accessing cobrand services. The very nature of such services enables many of these data capturing techniques to be utilized.
[0051] It will be apparent to one with skill in the art, that there may be more categories and subcategories included in this example without departing from the spirit and scope of the present invention. The inventor has outlined basic categories and basic subcategories and deems them sufficient for illustrative purposes. Therefore, the inclusion of such subcategories and categories in this example should not be construed as a limitation in any way.
[0052] It will also be apparent to one with skill in the art, that the unique cobrand architecture implemented between the service-providing entity of FIG. 1 represented by a server 15 and the plurality of cobrand partners utilizing CBS 23 - 27 , which are maintained by the same entity, enables multifaceted profiling of users to be accomplished in automated fashion. Therefore, much manual labor and research is eliminated from the data profiling process.
Target Information Generation and Ad-Serving
[0053] [0053]FIG. 3 is an overview of a communication network 45 wherein target advertisement based on evolutionary profiling is practiced according to an embodiment of the present invention. Communication network 45 includes a sub-network 49 , which in this example is the well-known Internet network and will hereinafter be referred to as Internet 45 . Internet 45 is the preferred medium used to interconnect various other components, which cooperate and communicate with each other through Internet 45 for the purpose of accomplishing the goal of the present invention, which is to provide a high level of ad compliance to user profiled states.
[0054] In a preferred embodiment of the present invention, Internet 49 , represented herein as a cloud, has a service provider 50 illustrated therein and adapted to provide a unique service that benefits users of the service, which includes users and advertisers. Service provider 50 comprises a file server 51 illustrated as connected to an Internet backbone 47 . Internet backbone 47 represents all lines, connection points and equipment making up the Internet network as a whole. Therefore, there is no geographic limitation the practice of the present invention. File server 51 is adapted as a portal server is so labeled. Server 51 represents the main user interface of service provider 50 . A mass storage repository 53 is illustrated within the domain of service provider 50 and connected to server 51 by virtue of a direct data link. Repository 53 is adapted to hold user profile information as so labeled. User profiles stored in repository 53 are generated in part at server 51 by recording user activity at the server.
[0055] A file server 55 is illustrated within the domain of service provider 50 and is connected to backbone 47 . Server 55 is adapted in part as a target ad server as so labeled, and in part as an in information generation server. A mass storage repository 57 is illustrated within the domain of service provider 50 and connected to server 55 by a high-speed data link. Repository 57 is adapted to store preference categories as so labeled. The term preference categories is defined in this specification as categories of user preferences mined from the user profiles held in repository 53 .
[0056] Servers 51 and 55 are interconnected, in this example, by a separate high-speed data network 52 . However, such connection is not required in order to practice the present invention as servers 51 and 55 may communicate with each other over Internet backbone 47 . Mass repositories 53 and 57 are illustrated in this example as external repositories. However, in other embodiments, they may be internal repositories within their respective servers. Also in other embodiments, one repository may be used as long as it is accessible to both servers 51 and 55 .
[0057] A plurality of ad partners 62 is illustrated within the domain of Internet network 49 and adapted via software and equipment to serve advertisements to target interfaces over Internet backbone 47 and through any sub-networks represented by backbone 47 . Ad partners 62 cooperate with service provider 50 in order to provide dynamic target advertising to both wireless device users illustrated herein by a dotted rectangle 65 , and connected PC users represented herein by a dotted rectangle labeled 63 .
[0058] In this example, there are two ad servers illustrated within the domain of ad partners 62 . These are server 59 and server 61 . Servers 59 and 61 are both connected to Internet backbone 47 . It is important to note herein that servers and 59 and 61 are adapted to serve advertisements and may be hosted by separate ad companies making up ad partners 62 . It will be apparent to one with skill in the art that there may be many more ad servers represented in this example without departing from the spirit and scope of the present invention. The inventor illustrates only two ad servers in this example and deems the illustration sufficient for explanation of the present invention.
[0059] Wireless device users 65 represents users who connect to Internet backbone 47 through Internet-capable appliances such as handheld computers and cellular telephones represented herein as icons illustrated within the domain of users 65 . PC users 63 represents users who connect to backbone 47 via a wired connection method such as the well-known dial-up/modem method. Sub-networks such as the well-known public-switched-telephony-network (PSTN) and cellular networks are not illustrated in this example but may be assumed to be present in represented in general by backbone 47 , which includes connected sub-networks. Similarly, Internet-service-providers (ISPs) and network gateways adapted to bridge wireless networks with Internet 49 are not illustrated but may be assumed to be present.
[0060] In this example, it is assumed that users 65 and users 63 login to Internet backbone 47 and access portal server 51 to receive various data-aggregation and summaries services known to the inventor. As such, user profiles represented in mass repository 53 are profiles compiled from demographic information and activity information obtained from users 65 and 63 on an ongoing basis. Such user profiles may be assumed to be the multifaceted profiles described with reference to U.S. patent application Ser. No. 09/654,320 listed in the cross-reference section of this specification. A goal of the present invention is to summarize and package user profiles contained in repository 53 into manageable data lists containing preference categories illustrated in repository 57 . This is accomplished by a software (SW) application 56 provided to execute, in this example, on server 55 .
[0061] Multifaceted profiling of users may include many user aspects including but not limited to data related to queries initiated; types of data collected from various data requests; the nature and description of Web-sites accessed; and access of frequently asked questions (FAQs) pertaining to a user's particular interests. Information concerning the data and/or product providers' response, behavior, on-line senescence, and other characteristic data of providers and services is learned and recorded by the profiling software. A user's multifaceted profile constantly evolves by virtue of learning new information about a user as profiling software continually tracks and updates recording new facets of user activity and online behavior.
[0062] SW 56 is adapted to access the multifaceted user profiles contained in mass repository 53 by virtue of high-speed data network 52 and is adapted to generate concise data lists of categorized, and in some cases, prioritized user-preference categories. The preference lists are generated to be small enough to easily be propagated through Internet backbone 47 . In one embodiment, SW 56 uses knowledge-based and data parsing techniques in order to summarize a multifaceted profile into a categorized and prioritized list of preferences for advertising purposes.
[0063] A software (SW) application 60 is provided to execute on ad servers hosted by entities making up ad partners 62 . In this example, an instance of SW 60 resides on server 59 and an instance of SW 60 resides on server 61 . SW 60 is, in a preferred embodiment, adapted to search for and deliver ads based on summary lists of categorized preferences delivered to respective host file servers 59 and 61 from server 55 , which in this example, functions as an ad broker. Ads delivered to server 55 from servers 59 and 61 are selected according to the appropriate theme or themes defined in the categorized preference lists used to invoke the ad delivery.
[0064] The ads received at file server 55 are rerouted through portal server 51 into appropriate Web interfaces accessed there from by users 65 and 63 using their respective appliances. This unique ad service is dynamic in nature meaning that a new, summarized preference list is generated each time one of users 65 or 63 logs into a personalized Web page served by server 51 . The generated preference list is, of course, derived from that user's multifaceted profile held in repository 53 . During the time required to download a personalized page from server 51 , the preference list is propagated to one or both of servers 59 and 61 where it is used as the criteria for selecting appropriate ads for routing into the personalized page. As a user's multifaceted profile evolves, so to does an associated preference list.
[0065] In another embodiment, server 55 may be adapted to function as a target information generation server, but not as an ad broker. In this case, ads delivered from server 59 and 61 would be propagated directly into server 51 during the appropriate time of Web-page service to a requesting user. However, in this embodiment preference lists are generated and sent to ad servers 59 and 61 at the beginning of page access by users.
[0066] Internet 49 is, in this example, the preferred data medium that hosts the data-aggregation and distribution system that is used to convey the preferred ad data to users via cable/modem, dial-up/modem, or satellite/modem transmission capabilities. In the embodiment depicted herein, the distribution of ad data may be made to any of users 65 employing wireless appliances such as the ones illustrated within the domain of box 65 , or to new devices being made available or in development at the time of this writing. Likewise, ad distribution may be accomplished via Internet 47 or the Internet and cable/modem networks to users of personal computers, Web TVs, computerized workstations, and other computer embodiments having network browsing and display capabilities. All that is required to practice the invention is a user have an appliance capable of accessing backbone 47 and server 51 through any one of a variety of known Internet-access methods.
[0067] In one embodiment of the present invention, users 65 and 63 may access the unique, dynamic ad service by connecting to any one of a plurality of cobranded-interface servers represented in FIG. 1 of Ser. No. 09/654,320 as cobrand servers (CBS) 23 - 27 . It is noted herein, that cobranded servers may be utilized in conjunction with a main portal server ( 51 ) as user interfaces to which ads may be delivered.
[0068] In one embodiment of the present invention SW 56 executing on server 55 within the domain of service provider 50 has the capability of generating categorized preference lists and the capability of polling ad sources (servers 59 and 61 ) for appropriate ads. This may be accomplished through an established prioritization scheme developed by service provider 50 and ad partners 62 . In this case, ads delivered into a particular interface may be sourced from more than one server. The exact prioritization scheme will depend on the nature of agreements forged. In this embodiment, preference categories held in repository 57 may not actually be sent to servers 59 or 61 of ad partners 62 . Rather, they may be used as search criteria for a search engine implemented as part of SW 56 . Such a search engine or polling software may be adapted to identify and retrieve ads from a plurality of ad servers represented by server 59 and 61 with the ads rated by percentage of match to the preference criteria.
[0069] According to another embodiment of present invention, SW 60 may be enhanced with a search engine adapted to search ads hosted by a host server 59 or 61 . In this case, a categorized preference list is sent to an appropriate ads server ( 59 , 61 ) according to contractual arrangement where in an internal search comprising ad identification and delivery is performed based on the received preference criteria.
[0070] A software application (not shown) provided to execute on server 51 operates in conjunction with mass storage repository 53 to obtain multi-faceted user profiles held in repository 53 (Ser. No. 09/654,320). As described in an embodiment of related application Ser. No. 09/654,320 such an application has the ability to record activity information related to any data request involving any of the servers navigating ad partners, data sources, and message traffic. In addition, the capability includes the ability to aggregate and categorize types of data requested and/or collected, types of inquiries initiated and data provided, and the variable categories and cost envelopes of purchases and/or deliveries. Moreover, identification and recording of the different types of interface devices employed by users 63 and 65 is also included in multi-faceted profiling.
[0071] It will be apparent to one with skill in the art that SW applications 56 and 60 may be provided of varying capabilities without departing from the spirit and scope of the present invention. For example, whether SW 56 includes polling capabilities, or whether preference lists are simply delivered to ad sources whereupon an internal ad search and delivery is conducted is left to practical design and implementation. The capability of delivering dynamic ads according to evolving user preferences wherein such ads are decided on during user-login and download of a WEB page represents a contribution to the art that is, at the time of this writing, not available.
[0072] [0072]FIG. 4 is a process-flow diagram illustrating various steps for dynamic ad serving based on received profile information according to an embodiment of the present invention. At step 67 , multi-faceted profiling is collected and recorded at the location of the service provider ( 50 ). Step 67 is an ongoing process including collection and recording of user data, on-line behavior characteristics, Internet activity, and preferences. The initial data is obtained from user-supplied information and stored by the service provider in mass storage repository 53 connected to portal server 51 of FIG. 3.
[0073] Initial profile data is augmented each time a user initiates on-line activity by supplementing the basic profile data with information related to user generated queries, investigations, purchases, on-line recreational activities and so on. It is noted herein that in addition to profile data obtained by virtue of automated process, profile data obtained from manual process may also be included as referenced in U.S patent application Ser. No. 09/654,320.
[0074] At step 69 , a specific user profile is accessed and mined for summary data, which is organized into a categorized and, in some cases, prioritized preference list. Step 69 results from a user request and process of logging into a personalized Web interface served by portal server 51 of FIG. 3, or from a described cobrand server functioning as the interface. Data (profile) access, mining and organization is accomplished by software (SW 56 ) through the use of a knowledge-base technique or other rules-base scheme. For example, a knowledge database may contain a plurality of listed categories and descriptive keywords associated with those categories. Category titles may be adopted into a preference list by priority of number of matching hits to descriptive words contained in a multifaceted profile.
[0075] The results obtained in step 69 will be slightly different each time the process occurs by virtue of continual updating and purging of a user's multifaceted profile. Incorporation of new user preferences, traits, habitual or spontaneous site visits, ad or sponsor clicking and so on this ultimately reflected in a categorized preference list generated in step 69 .
[0076] At step 73 , a categorized preference list is temporarily stored in a repository (repository 57 , FIG. 3) connected to a target ad server (server 55 , FIG. 3). It is noted herein, that step 73 reflects one embodiment wherein preference lists are not sent out to ad servers but are held at the service provider. Also at step 73 , ads received from various ad partners in step 81 are collected and classified into appropriate preference categories and stored in an ad database, which may be searched using a preference list as a search criteria and a search function provided as part of SW 56 . In this case, ad identification and prioritized association with a received preference list is performed by one machine within the domain of the service provider.
[0077] According to another embodiment, step 73 comprises immediate receipt and propagation of preference lists to ad servers ( 59 and 61 of FIG. 3) hosted by ad partners ( 62 of FIG. 3) wherein ad identification, association and delivery according to data contained in a preference list is performed by distributed software ( 60 of FIG. 3). The preference category and user profile information 71 are continually updated and provided to the target ad server where the user profiles are catalogued and matched with the products and services of the ad partners, FIG. 3 element 59 .
[0078] Referring now back to the process described in this example, ads generated by ad partners in step 81 are made available to target ad server ( 51 ) by various agreements forged between the parties involved. The provided ads can be associated under generic categories or can be, in some cases, personalized to various users or groups of users based on demographic data obtained previously obtained during repeated execution of dynamic ad serving. Available ads are limited only by the agreements between the ad partners and the service providers and in all cases are established with the needs and preferences of the users in mind. The products and services of the ad partners are made available as pop-up banner ads, static banner ads, pop-up text ads, static text ads, or other inventive techniques developed by the parties involved.
[0079] Step 73 provides, in this example, both the receipt of dynamic user-preference lists and the classification and collation of ads into preference categories (ongoing) and matching of appropriate ads to preference lists in process. Matching of stored ads to received preference lists is accomplished using a database search function. In one embodiment, the search function employs a priority-coding scheme to expedite matching of ads to user-preference lists.
[0080] At step 75 , the target ad server serves selected ads to the appropriate user interface identified in the particular user-preference list. In this example, the target ad server (server 51 of FIG. 3) functions as an ad broker. However, in other embodiments, ads may be served directly to user interfaces from remote ad servers. In a case such as this, user preference lists would be propagated directly to such ad servers and server 51 of FIG. 3 would be responsible only for target information generation (generating preference lists). It is noted herein, that step 69 , 73 , and 75 occur during the small amount time required for a user to login and access a personalized Web page.
[0081] At step 77 , graphical ads are delivered to user interfaces associated with wired PCs, laptops, and other appliances having suitable capabilities for graphical display. At step 79 , textual ads are delivered to wireless users accessing their personalized pages via cellular phones, handheld computers, two-way pagers, and other Internet-capable wireless appliances. It is noted herein that in some cases of display, graphical ads may be reduced somewhat for wireless interfaces but still retain some graphical integrity. Similarly, interfacing devices suited for more elaborate graphical displays may still, in some cases, receive only text ads.
[0082] It will be apparent to one with skill in the art, that the process steps illustrated in this example are exemplary only and may be presented in a number of different orders and descriptions representing various embodiments without departing from the spirit and scope of the present invention. For example, in an embodiment where ad matching to preference criteria is performed outside of the domain of the service provider such as within the domain of ad partners, a step would be included for delivering categorized preference lists to various target ad servers hosted by associated ad partners. The inventor intends that the exemplary steps illustrated herein represent just one of many possible processes that may define dynamic ad serving based on evolving user preferences.
[0083] In one embodiment of the present invention, the process of polling data sources for data that may be matched to generated preference lists may incorporate embodiments wherein banner and text ads are just a few of the types of advertisements that may be routed into an interface. For example, in addition to ads normally served by ad servers, the method and apparatus of the present invention may be expanded to include email advertisements and other types of instant messaging advertisements.
[0084] In still another embodiment of the present invention the existence of a concise and packaged preference list can be utilized in addition to search phrases or keywords entered into a conventional search engine in order to provide a list of URLs that most closely and match actual user preferences that may in some way relate to the executed data search. In this case distributed software would be required at the database locations hosted by the entities providing the data search services. In all aspects of the present invention, the processes of generating a preference list, identifying and associating ads to the preference list, and delivering the selected ads to the user on all accomplished during the time window a user utilizes in the process of accessing and downloading a personalized Web page. Ads presented within a personalized Web page will evolve with regards to content at the rate that the associated user profile evolves with regards to content.
[0085] The method and apparatus of the present invention may be practiced on any DPN that supports the appropriate Internet protocols. Furthermore, there's no limit to the number of cobrand partners, or end-users that may participate in the practice the present invention. Therefore, the method of the present invention should be afforded the broadest possible scope under examination. The spirit and scope of the present invention is limited only by the claims that follow. | An advertisement selection and delivery system for selecting advertisements based on profile information and rendering the advertisements as accessible to a user operating a network-capable appliance connected to a data-packet-network is provided. The system comprises, a first server node connected to the network, the first server node functioning as a user access point on the network, a mass storage repository accessible to the first server node, the repository for storing and serving user profile data, a second server node connected to the network, the second server node for generating user preference data, at least one advertisement server connected to the network, the advertisement server for serving advertisement data, a software application for generating user preference lists and performing advertisement selection and at least one network-capable appliance connected to the network the network-capable appliance for receiving the advertisement data. A user operating the network-capable appliance accesses the first server node and receives the advertisement data, the advertisement data selected for service by matching the user preference data to stored advertisements and rendered accessible to the user during the time of user access to the system from the network-capable appliance. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to control of nitrogen oxides emitted from combustion devices. The invention will be most useful on furnaces, boilers, steam generators, and heaters which function in some respects in a manner similar to furnaces. The invention consists of an apparatus and method for reducing the formation of nitrogen oxides in roof-fired furnaces by the staged addition of combustion air.
2. Description of the Prior Art
Nitrogen oxides ("NOX") emitted from combustion devices are a major regulatory concern in many industrialized countries. Nitrogen oxide ("NO"), which is the usual form of NOX emitted from furnaces, is converted to nitrogen dioxide ("NO2") in the atmosphere in a matter of a few hours or days after emission. NOX emissions are currently the subject of strict regulatory control. Among the objectives of these regulations are: reduction of acid rain, reduction of smog, reduction of eye and respiratory irritation, and reduction of formation of ozone. Some laws and regulations governing NOX emissions have been in force for 25 years. Additionally, even more stringent regulatory control will become effective after 1995.
Empirical studies have identified two mechanisms for the formation of NOX in pulverized coal-air flames: (1) thermal reaction of nitrogen and oxygen contained with combustion air to form NOX ("thermal NOX"), and (2) the oxidation of organically bound nitrogen compounds contained within coal to NOX ("fuel NOX"). For conventional furnaces, thermal NOX formation becomes significant at temperatures above 2800° F. Conversion of fuel-bound nitrogen to NOX can occur at much lower temperatures. Empirical studies have revealed that fuel NOX represents a substantial portion of the total NOX formed in a pulverized coal flame.
The reactions involved in the formation of thermal NOX are generally regarded to be:
(1) O2=O+O
(2) O+N2=NO+N
(3) N+O2=NO+O
(4) N+N=N2
Reaction 1 is an equilibrium reaction and the atomic oxygen formed in this reaction is in equilibrium with the molecular oxygen ("O2"). The relative equilibrium concentrations of Reaction 1 is very temperature dependent and the amount of atomic oxygen is very small below 2800° F. Also, the total amount of atomic oxygen is dependent upon the concentration of molecular oxygen in the combustion zone.
Atomic oxygen formed in Reaction 1 can react with molecular nitrogen to form NO and N, as shown in Reaction 2. Atomic nitrogen, which is formed in Reaction 2, is converted at an efficiency of 5 to 50 percent to NO, as shown in Reaction 3, depending upon the availability of molecular oxygen in the combustion zone. If the concentration of molecular oxygen is low, then the dominant reaction for atomic nitrogen will be Reaction 4 that results in molecular nitrogen ("N2"). N2 is the desired reaction product. These reactions have been studied, described, and quantified by Zeldovich. Zeldovich, Ya. B." Acta Physicohin, USSR, 21,577. Therefore, to avoid thermal NOX formation, it is important to control the amount of coal that is burned in the combustion zone at temperatures above 2800° F. and to minimize the amount of excess oxygen in the combustion zone.
Fuel NOX is formed when fuel-bound nitrogen reacts with atmospheric oxygen. Fuel-bound nitrogen becomes atomic nitrogen (or part of a very reactive radical) when oxygen consumes the hydrocarbon molecule in which the fuel-bound nitrogen was originally located. Once atomic nitrogen becomes available in the combustion zone, it can react with molecular oxygen (Reaction 3) or it can react with another atomic nitrogen (Reaction 4). Reaction 3 is favored and NO is formed at efficiencies up to 50 percent, if there is excess air (which results in excess oxygen) present in the combustion zone. However, if there is little or no excess oxygen when the atomic nitrogen is liberated from the fuel, then Reaction 4 is favored and N2 is formed at efficiencies up to 90 percent.
Fuel-bound nitrogen contained in the volatile fraction of coal will be burned quickly because the volatile fraction of coal is evolved and burned within the first 200 milliseconds of combustion. This first 200 milliseconds represents the period in which atomic nitrogen from fuel-bound nitrogen in the volatile fraction is available for reaction. Therefore, to avoid fuel NOX formation, it is important to minimize or eliminate the amount of excess oxygen in the combustion zone where atomic nitrogen is formed.
NOX emissions from furnaces have been the subject of regulatory scrutiny for many years. Many successful devices and procedures have been used to reduce NOX emissions from furnaces. Fuels such as natural gas have no fuel-bound nitrogen and NOX emissions can be reduced by lowering flame temperatures. Reduced air preheat, flue gas recirculation and water injection have been used in various types of furnaces to reduce NOX emissions from natural gas combustion. However, these techniques are not effective in reducing the formation of fuel NOX. Oil fuel, which has some fuel-bound nitrogen, has sometimes been treated with the techniques used in natural gas combustion, but they are only partially effective.
The content of nitrogen by weight of coals typically burned by utilities can vary from 0.3% to over 2.0%. A coal having 1% nitrogen by weight and a heating value of 12,000 Btu per pound would emit the equivalent of 0.5 pounds of NOX per million Btu's, if only 20% of the fuel-bound nitrogen was converted to NOX. Any thermal NOX would add to this amount. Therefore, to meet expected emission limits and current limits for some furnaces (0.5 pounds of NOX per million Btu's of heat input) it is necessary that no more than 20 percent conversion of the fuel-bound nitrogen be converted into NOX. Numerous techniques have been tried to achieve these goals.
Slowly mixing or controlled mixing burners have been used on face fired and tangential fired furnaces to reduce NOX emissions. While some success has been achieved with this method, they are expensive and may result in increased carbon in the fly ash. Increased fly ash carbon can disrupt the functioning of the particulate removal devices and may cause destructive and dangerous fires in the back end of the combustion device. Controlled mixing burners have also been tried on roof-fired furnaces, but their application has been limited.
Many roof-fired furnaces have uniquely designed fuel delivery and burner systems. In these systems, coal is pulverized or milled so most of the coal will pass through a 70 mesh screen. The milled coal is then blown into the furnace by 10 to 25 percent of the combustion air. The coal and air from the pulverizer is divided into several pipes, each pipe supplying a burner which is typically 12 to 48 inches in diameter. This coal pulverization and delivery system is typical of many furnaces, but in some roof-fired furnaces the coal burner is further divided into 4 to 16 nozzles before the air and coal is discharged into the furnace. The burners are located in the roof of the furnace and the fuel is fired vertically downward. Different furnaces will have different numbers of pulverizers, burners, and nozzles per burner. These nozzles are only about 1 to 3 inches in diameter. The secondary air also is supplied through openings which usually are not more than 4 inches wide. Typically, there are multiple secondary air openings for each nozzle. The small size of these nozzles and secondary air openings allows the coal, primary air, and secondary air to be discharged into the furnace through spaces between boiler tubes in the roof of the furnace. This type configuration is known as a multi-nozzle, inter-tube burner.
To retrofit roof-fired furnaces which currently employ the multi-nozzle, inter-tube burner with low NOX burners requires substantial modification to the furnace roof. The furnace top for roof-fired furnaces is usually defined by boiler tubes between which there are spaces. The nozzles and the secondary air pass through these spaces. These tubes must be cut out and replaced with bent sections to allow new low NOX burners to be installed. This can be an expensive retrofit.
Another type of retrofit is the addition of NOX ports or overfire air ports. Typically, low NOX burners are installed in combination with overfire air ports. With overfire air ports, some combustion air is diverted from the burners and supplied to the overfire air ports. This results in the early stages of combustion (about 0.2 to 0.5 seconds) occurring in a fuel-rich environment. Because fuel-bound nitrogen contained within the volatile portion of coal is generally evolved during the first 200 milliseconds of combustion, the overfire air enters the combustion process after this fuel-bound nitrogen has been liberated. Because this fuel-bound nitrogen is liberated in a fuel-rich environment, it will preferentially react with atomic nitrogen to form N2 and will not react with molecular oxygen in significant amounts to form NOX. Further, because of the delayed addition of combustion air from the overfire air ports, the average combustion temperature has been reduced by heat transfer to the boiler tubes. This lowering of the combustion temperature will reduce thermal NOX formation.
However, the system just described has numerous drawbacks when applied to a roof-fired unit that uses nozzles to discharge coal into the furnace. Installation of the low NOX burners and overfire air ports requires modification and replacement of many boiler tubes in the furnace roof. The wind box must be converted to accommodate new and expensive low NOX burners. Duct work must be installed to bring overfire air from existing duct work or the windbox to the overfire air ports. Refractory throats must be constructed for both the burners and the overfire air ports. Dampers must be installed for the overfire air ports. Typically, when overfire air ports are installed, there is no easy method of adjusting the distribution of combustion air to assure substantially complete combustion while achieving the required level of NOX reduction.
As shown above, economical methods of retrofitting low NOX systems to roof-fired furnaces using multi-nozzle, inter-tube burners are not generally available. Such systems as are available have experienced only limited testing with natural gas, fuel oil, and pulverized coal.
Various back end or post combustion treatments to reduce NOX after it has been formed during combustion are available and are used in certain situations. One process is referred to as thermal deNOX, non-catalytic deNOX, or selective non-catalytic NOX reduction ("SNCR"). Another process is referred to as selective catalytic NOX reduction ("SCR"). Both of these require ammonia ("NH3"), a toxic and difficult to handle gas or pressurized liquid. SNCR requires very careful injection of vaporized and diluted ammonia at a very narrow temperature window which may move in the furnace as load or other conditions change. SCR require a very expensive catalyst. These systems are so expensive as to be practical only where the most stringent laws are in force and after the less-expensive measures to reduce NOX formation during combustion have been taken. Further, these deNOX processes are usually applied to furnaces which only fire natural gas or oil.
Reburn, or in-furnace NOX reduction, is a technique where a fuel, usually natural gas or other high grade and expensive fuel which contains little or no fuel-bound nitrogen, is introduced in the furnace well downstream of the burners. The fuel is introduced in sufficient quantities to cause the gas stream to be fuel-rich. Temperatures of about 2000° F. to 2400° F. are desirable for this process but they are not always available before the gases flow through the convective passes of the furnace. The NO in the gas stream reacts with the fuel to form carbon dioxide, water vapor, molecular nitrogen, and fixed nitrogen compounds, such as, ammonia, hydrogen cyanide, and amines. Then enough additional air is provided to complete the combustion substantially and to make the gas fuel lean, preferably at the lower end of the temperature range. The fixed nitrogen compounds are oxidized to NO, and molecular nitrogen. Through this process the NOX is reduced by about 50%. The process is expensive to implement and reburn fuels are more expensive than coal. Additionally, many furnaces do not have sufficient volume to accommodate reburn.
The vertical or roof-fired design which is of primary concern to the present invention, involves the use of multiple burners. Each burner is subdivided into multiple individual fuel nozzles. The burners are located in the roof of the furnace and the fuel is fired vertically downward. Secondary air is introduced through roof openings which surround the fuel injection nozzles. Different furnaces will have different numbers of pulverizers, burners, and nozzles per burner.
The roof-fired design represents a relatively unique style of furnace that was designed and constructed in the late 1940's and early 1950's. The nitrogen oxide emissions from these units have not been extensively studied by applicants, but the emissions are believed to be above levels allowed by current or future regulations. Existing NOX reduction technology can not be easily applied to these roof-fired units. A retrofit using existing NOX reduction technology is expensive, costing approximately six to seven times the cost of a conventional wall-fired furnace retrofit. Consequently, there is a need for a combustion apparatus and method which will reduce nitrogen oxide emissions in flue gas and which can be readily used in existing roof-fired furnaces.
Kochey, U.S. Pat. No. 4,316,420, discloses the introduction of a greater portion of the combustion air flow at a location remote from where the fuel is initially burned.
Michelson, et al., U.S. Pat. No. 4,629,413, discloses blocking off secondary air openings near the fuel burner and reintroducing the secondary air at a remote location.
Hellewell, et al., U.S. Pat. No. 5,020,454, discloses the use of overfire air nozzles to inject overfire air at locations remote from the coal burner.
Yap, U.S. Pat. No. 5,229,929, issued, discloses the use of secondary air nozzles to achieve staged combustion.
SUMMARY OF THE INVENTION
The present invention provides an apparatus and method for reducing the formation of NOX during combustion in a roof-fired furnace. This is accomplished by a parallel flow air system where a portion of the combustion air is removed before it is introduced into the furnace and is introduced into the furnace roof at a location separated from the burners. The separated parallel flow overfire air ("SPFOFA") is taken from the secondary air duct and conducted to the top of the furnace at a location separate from the burners. From 10 to 40 percent of the air will be diverted, allowing initial combustion to occur in either a fuel-rich or a just slightly fuel-lean environment.
In many roof-fired furnaces the distance from the secondary air duct to the outside of the furnace roof is 5 feet or less. This short distance allows several SPFOFA ports to be installed with a minimum of expense.
Each air port can be fitted with a damper. Each port can be supplied with directional vanes which can divert the air into the combustion products or away from the combustion products as dictated by the performance results.
In the case of a nozzle-burner arrangement or other arrangement where the furnace roof is formed by boiler tubes with spaces between them, the SPFOFA can flow between the tubes. The SPFOFA ports may be partially blocked by the tubes, but no tubes will need to be cut out and replaced.
The system of SPFOFA flow can be used in roof-fired furnaces with the original burners whether they are the finger type burners or round register burners, and it can be used with replacement low NOX burners. The SPFOFA flow will reduce the oxygen available in the initial combustion zone and thereby reduce the NOX emissions. However, the air to fuel ratio in the primary flame zones will often be reduced to levels below the amount of oxygen needed to burn the fuel. The air entering through SPFOFA ports will mix with the hot, fuel-rich combustion products and substantially complete the combustion before the products exit the furnace.
In some cases the actual fuel to air ratio in the primary flame zone will continue to be fuel-lean. In this case the lowering of the excess air in this region will lower NOX emissions,
SPFOFA flow will deprive the primary flames of some of the air needed for combustion. This, in conjunction with the slow mixing in the primary flame zone, especially the intentionally slow mixing caused by low NOX burners, will result in the volatile matter in coal being burned in an initially fuel-rich environment. Since only about 15% to 35% of fuel in coal is volatile matter, the flame where this is burned must contain less than 15% to 35% of the air required for substantially complete combustion, if the volatile matter is to burn in a fuel-rich environment. Since the deepest NOX reduction requires the volatiles, which contain much of the fuel bound nitrogen, to be burned in a fuel-rich environment, and less than half of the air will be introduced as SPFOFA, the burner itself must also retard and control mixing. These concerns equally apply to reducing the formation of thermal NOX.
SPFOFA extends the completion of flame to positions well down in roof-fired furnaces. The extended flame, in conjunction with prompt ignition of mixture of primary air and pulverized coal as it enters the furnace, results in initial combustion occurring under fuel-rich conditions.
Accordingly, it is an object of the present invention to provide a simple and inexpensive apparatus and method to alter existing roof-fired furnaces so that the amount of NOX formed during combustion is reduced. It is a further object of the present invention to provide an apparatus and method of reducing NOX emissions using separated parallel flow overfire air. It is yet another object of the present invention to create a fuel-rich environment for the initial combustion of pulverized coal.
These and other advantages and features are accomplished by the present invention which is more fully understood by reference to the drawings and the detailed description of the presently preferred embodiments thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a is an overview of a furnace that is fired vertically from its roof.
FIG. 1b is an overview of a furnace that is fired vertically from its roof. The system for distributing secondary air and the system for distributing pulverized coal and primary air are omitted for clarity.
FIG. 2 shows a typical arrangement of diversion of secondary air to SPFOFA ports.
FIG. 3 shows the effect of SPFOFA damper position on NOX emissions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will be described in further detail by way of a preferred embodiment, particularly as shown in FIGS. 1a, 1b, and 2.
Referring to FIGS. 1a, 1b, and 2, an improved apparatus and method for reducing the formation of NOX in a conventional inter-tube roof-fired furnace 10 has been shown. Roof-fired furnace 10 is modified by re-directing some secondary air 11 so that it enters roof-fired furnace 10 at a location separate from roof burners 12.
Combustion air 13 is split into two streams: primary air 14 and secondary air 11. Primary air 14 goes to pulverizer 15 and mixes with pulverized coal 16. The resulting mixture of pulverized coal and air 17 flows to roof burners 12. From roof burners 12, mixture of pulverized coal and air 17 is burned in roof-fired furnace 10. Adjacent each roof burner 12 is a secondary air opening 18 that discharges secondary air 11 into roof-fired furnace 10. Secondary air 11 is transported to secondary air opening 18 via duct 19. Secondary air 11 mixes with combustion products 26 that are formed from the ignition of pulverized coal and air 17.
A portion of secondary air 11 is withdrawn from duct 19 and is introduced into roof-fired furnace 10 as separated parallel flow overfire air ("SPFOFA") 20. SPFOFA 20 is introduced into roof-fired furnace 10 through a plurality of SPFOFA ports 21 at a location separate from roof burners 12. Each SPFOFA port 21 is equipped with a damper 22 that allows for adjustment of the amount of SPFOFA 20 that flows through SPFOFA port 21. This withdrawal of SPFOFA 20 from secondary air 11 creates either a fuel-rich or just slightly fuel-lean environment adjacent roof burners 12. SPFOFA port 21 may be the terminus of a converging nozzle that directs SPFOFA 20 from duct 19 to SPFOFA port 21.
By introduction of SPFOFA 20 at a location separate from roof burner 12, NOX formation is reduced in two ways. First, fuel NOX formation is reduced by conducting the initial stages of combustion in a fuel-rich environment. Second, thermal NOX formation is reduced because the separate introduction of SPFOFA 20 lengthens the combustion zone in roof-fired furnace 10. This lengthened combustion zone can be more readily cooled by heat transfer to boiler tubes 23 that form the sides of roof-fired furnace 10 and boiler tubes 24 that form roof 25 of roof-fired furnace 10.
In one embodiment, a plurality of rows of SPFOFA ports 21 are located separate from each roof-burner 12. The plurality of SPFOFA ports 21 are positioned so that the rows are different distances from roof-burners 12. In this manner how quickly SPFOFA 20 mixes with combustion products 26 can be adjusted by dampers 22 to regulate how closely SPFOFA 20 is introduced to roof-burner 12. By varying how closely SPFOFA 20 is introduced to roof-burner 12, the length of time that initial combustion occurs in a fuel-rich or slightly fuel-lean environment can be controlled. In one embodiment, the amount of SPFOFA 20 that is introduced into roof-fired furnace 10 is about 15% to 40% of the total amount of combustion air 13. In one embodiment, SPFOFA ports 21 are equipped with vanes 27. Vanes 27 allow SPFOFA 20 to be directed either toward or away from roof-burner 12. In one embodiment roof-burner 12 uses a plurality of nozzles 28 to discharge mixture of pulverized coal and air 17 into roof-fired furnace 10. In one embodiment, roof-burner 12 is a low NOX burner. In one embodiment, roof boiler tubes 24 have refractory material 29 in between adjacent boiler tubes 24. In this embodiment enough refractory material 29 is removed to allow SPFOFA 20 to enter roof-fired furnace 10 through SPFOFA ports 21. Steel membrane 31 may be present between adjacent boiler tubes 24 either in place of refractory material 29 or in addition to refractory material 29.
In one embodiment roof boiler tubes 24 are covered with studs 30. In this embodiment, studded roof boiler tubes in the area adjacent SPFOFA ports 21 are removed and replaced with roof boiler tubes that are not studded. In another embodiment, studs 30 are removed from roof boiler tubes 24.
In one embodiment SPFOFA ports 21 are located between roof-burner 12 and a rear wall of roof-fired furnace 10. In one embodiment SPFOFA ports 21 are located between roof-burner 12 and a division wall of roof-fired furnace 10. In one embodiment SPFOFA ports 21 are located between roof-burner 12 and a front wall of roof-fired furnace 10. In one embodiment SPFOFA ports 21 are located between roof-burner 12 and both the front and rear walls of roof-fired furnace 10.
EXAMPLES
Examples 1 and 2 are given for a roof-fired furnace operated without the invention, so a comparison with these results can be used to determine how much improvement the invention makes. Examples 3, 4, 5, 6, 7, 8, 9, 10, and 11 illustrate the use of the invention. The Duquesne Light Company Elrama 1 furnace burning bituminous coal was used for all of the test examples.
Examples 1 and 2: Duquesne Light Company's Elrama 1, a roof-fired furnace, with two pulverizers, eight burners and 12 nozzles per burner. The furnace was operated at 91 megawatts ("MW") and no SPFOFA was used. The results were: NOX emissions were 0.72 pounds, as NO2 per million Btu ("MMBtu") and carbon monoxide ("CO") levels in the flue gas were 24 ppm. In a second baseline test, the furnace was operated to generate 96 MW with no SPFOFA and there results were: NOX emissions at 0.78 lb/MMBtu and CO at 23 ppm.
Example 3: Elrama 1 was equipped with two rows of SPFOFA ports which in total have the capacity to supply as much as 33% of the secondary air. The rear SPFOFA ports are more remote from the burners than the front SPFOFA ports. There are a total of 16 SPFOFA ports which allow air to flow down between boiler tubes that form the roof of the furnace. Each SPFOFA port has a damper. The air flows down through the roof, parallel to the primary air and coal and the secondary air. SPFOFA can be directed through the ports closest to the burners which causes it to mix sooner and better control burn out, carbon monoxide and carbon in the ash. Alternatively, SPFOFA can be directed through the ports furthest from the burners, which lowers NOX emissions. 0r SPFOFA can be directed through both sets of burners. In this example, rear SPFOFA dampers were opened half-way (50%) and front SPFOFA dampers were closed (0%). This combination resulted in SPFOFA dampers being set at an aggregate 25% level. The unit was operated at 91 MW and the results were: NOX emission at 0.64 lb/MMBtu and CO at 16 ppm.
Examples 4 and 5: Elrama 1 modified as explained in Example 3, and was operated with the rear SPFOFA dampers fully open (100%) and the front SPFOFA ports at 0%. This combination resulted in the SPFOFA dampers being set at an aggregate 50% level. In Example 4 the unit was operated at 91 MW and the results were: NOX emissions at 0.55 lb/MMBtu and CO at 25 ppm. In Example 5, the unit was operated at 96 MW and the results were: NOX emissions at 0.62 lb/MMBtu and CO at 26 ppm.
Example 6, 7, and 8: Elrama 1 with the SPFOFA capability as explained in Example 3 was operated with the rear SPFOFA dampers at 100% and the front SPFOFA ports at 50%. This combination resulted in the SPFOFA dampers being set at an aggregate 75% level. In Example 6, the unit was operated at 96 MW and oxygen in the flue gas leaving the economizer was measured at 5.4%. The results were: NOX emissions at 0.35 lb/MMBtu and CO at 380 ppm. In Example 7, the unit was operated at 96 MW and oxygen in flue gas leaving the economizer was measured at 6.0%. The results were: NOX emissions at 0.40 lb/MMBtu and CO at 65 ppm. In Example 8, the unit was operated at 96 MW and the results were: NOX emissions at 0.44 lb/MMBtu and CO at 59 ppm.
Example 9: Elrama 1 with the SPFOFA capability as explained in Example 3 was operated with the rear SPFOFA dampers at 0% and the front SPFOFA dampers at 100%. This combination resulted in the SPFOFA dampers being set at an aggregate 50% level. The unit was operated at 96 MW and the results were: NOX emissions at 0.64 lb/MMBtu and CO at 23 ppm.
Example 10: Elrama 1 with the SPFOFA capability as explained in Example 3 was operated with the rear SPFOFA dampers at 50% and the front SPFOFA dampers at 50%. This combination resulted in the SPFOFA dampers at an aggregate 50% level. The unit was operated at 96 MW and the results were: NOX emissions at 0.55 lb/MMBtu and CO at 29 ppm.
Example 11: Elrama 1 with the SPFOFA capability as explained in Example 3 was operated with the rear SPFOFA dampers at 50% and the front SPFOFA dampers at 100%. This combination resulted in the SPFOFA dampers at an aggregate 75% level. The unit was operated at 96 MW and the results were: NOX emissions at 0.52 lb/MMBtu and CO at 32 ppm.
These examples show the improvement made by this unique overfire air system which provides SPFOFA adjacent burners in the roof of a roof-fired furnace. In some cases, NOX reductions of over 50% were achieved. The CO remained low in Example 6 although the 380 ppm may be higher than desired. This emission level of 0.35 lb/MMBtu is well below most expected limits for roof-fired furnace. Example 7 shows that the carbon monoxide can be decreased by increasing the air flow and yet the NOX, at 0.40 lb/MMBtu, was well below most widespread current limit of 0.50 lb/MMBtu. Example 11 showed unexpectedly good combustion efficiency as measured by the amount of unburned carbon in the flyash.
FIG. 3 shows NOX emissions as a function of aggregate SPFOFA damper level. At a 75% level, the SPFOFA supplies about 24% of the secondary air needed to burn substantially the pulverized coal. Reductions in NOX emissions over the base-line tests were achieved with the SPFOFA dampers set at an aggregate 75% level.
While a present preferred embodiment of the invention is described, it is to be distinctly understood that the invention is not limited thereto but may be otherwise embodied and practiced within the scope of the following claims. | An improved method and apparatus for supplying combustion air in a roof-fired furnace. Part of the combustion air, overfire air, enters through the roof of a roof-fired furnace at positions separate from the coal burners. The separated entry of overfire air ensures that the initial stages of combustion occur in a fuel-rich environment. A fuel-rich environment during the early stages of combustion favors the formation of molecular nitrogen and disfavors the formation of nitrogen oxides during combustion. The overfire air flows roughly parallel to the flow of combustion products emanating from the coal burners. The overfire air can be angled by vanes either slightly towards or slightly away from the combustion products, depending on how long combustion needs to be retarded in order to inhibit the formation of nitrogen oxides. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to the synthesis of novel synthetic resins wherein a N,N*-substituted disulfonamide is copolymerized with either an organic acid dichloride or diisocyanate. The principle object of this invention is the demonstration of the synthesis of novel synthetic resins from N,N*-disubstituted disulfonamides. More specific objectives and advantages are apparent from the description, which discloses and illustrates but is not intended to limit the scope of the invention.
The global production of resins in multibillion-pound quantities includes polycarbonates and epoxy resins. The bulk of these resins utilize bisphenol-A. Recent research (Current Biology, Volume 13, page 546, 2003) has shown that abnormalities in developing mouse eggs occurred at levels of bisphenol-A from hydrolysis of bisA polycarbonate. Similar aberration in human eggs would lead to miscarriages and birth defects. The bisphenol-A epoxy resin is based on the following technology, which requires no less than twelve chemical transformations as illustrated below:
benzene+propylene→isopropylbenzene
isopropylbenzene→cumene hydroperoxide
cumene hydroperoxide→phenol+acetone
phenol+acetone→bisphenol A (bisA)
propylene+chlorine→allyl chloride+hydrochloric acid (HCl)
allyl chloride+sodium hydroxide+chlorine→propylene chlorohydrins
propylene chlorohydrins+sodium hydroxide→epichlorohydrin
bisA+epichlorohydrin→bisA chlorohydrin
bisA chlorohydrin+sodium hydroxide→bisA diepoxide
bisA diepoxide+bisA→epoxy resin
sodium chloride+water−>chlorine+sodium hydroxide
waste chlorinated byproducts+hydrogen→HCl+hydrocarbons
The reaction sequence has several negative process implications with regards to yields of chlorinated byproducts, hydraulic load as well as the above-mentioned biological problem. Benzene is a known carcinogen and the process for the production of epichlorohydrin produces considerable quantities of chlorinated byproducts. In addition, the process requires a chlor-alkali facility, hence a local supply of salt and copious quantities of water. The products and processes of the present invention ameliorate some of the disadvantages of the prior art of the products and processes.
BRIEF DESCRIPTION OF THE INVENTION
The present invention relates to the preparation of novel condensation polymers wherein N,N*-disubstituted disulfonamides are co polymerized with either an organic acid dichloride or a diisocyanate. Organic acid dichlorides may be selected from any of the following: dicarboxylic acid dichlorides, disulfonic acid dichlorides, phosphoric acid dichlorides, phosphonic acid dichlorides, bischloroformates and phosgene. N,N*-disubstituted disulfonamides may be prepared from either a disulfonyl dichloride and an organic amine, or from an organic diamine and a sulfonyl chloride, and have the formulas:
RN(H)SO 2 R*SO 2 N(H)R (1a) and
RSO 2 N(H)R*N(H)SO 2 R (1b),
where R is a monovalent hydrocarbon alkyl aryl, aryl-alkyl, alkyl-aryl radical of 1–20 carbon atoms or a monovalent inertly substituted hydrocarbon aryl, alkyl, alkyl-aryl or aryl-alkyl radical of 1–20 carbons atoms and R* is a divalent hydrocarbon arylene, alkylene, alkylene-aryl, arylene-alkyl radical or combinations thereof of 2–20 carbon atoms or an inertly substituted divalent hydrocarbon alkylene, arylene, arylene-alkyl, or alkylene-aryl radical or combinations thereof of 2–20 carbon atoms. The term “inertly substituted” is defined as meaning substituents on the hydrocarbon radicals that do not interfere in the reaction scheme employed to prepare the novel polymers of the present invention. Such substituents would be apparent to those skilled in the art from the reactions set forth and are primarily halogen, ether, ester and amide substituents. Preferred mono and divalent aromatic moieties are derived from hydrocarbons, which include but are not limited to benzene, naphthalene, toluene, chlorobenzene, xylene, biphenyl, phenyl ether, phenyl sulfone and benzophenone. Preferred aryl alkyl moieties include but are not limited to benzyl, bibenzyl, 1,2-diphenoxyethane, 1,4-diphenoxybutane. Preferred alkyl moieties include but are not limited to ethyl, propyl, hexyl, octyl, cyclohexyl and methoxyethyl.
The comonomers used in forming the condensation polymers of the present invention are organic diacid halides, and preferably chlorides or diisocyanates, which have the general formula:
X—R**—X (2)
When X is —COCl, (2) is a dicarboxylic acid dichloride (2a), when X is —SO 2 Cl, (2) is a disulfonic acid dichloride (2b); when X is —OCOCl, (2) is a bis chloroformate (2c); when X is —OP(O)(OR) 2 )(2) is a diphosphoric acid ester (2d); when X is —P(O)(OR) 2 , (2) is a diphosponic acid ester(2e); -when X is —Cl, (2) is phosgene (2f), and when X is —NCO, (2) is a diisocyanate (2g). R** includes R* as defined above and —CO— derived from phosgene. The repeating units of the polymers of the present invention can be represented by the following formulas:
—N(R)SO 2 R*SO 2 N(R)C(O)R**C(O)—
3aa
—N(R)SO 2 R*SO 2 N(R)SO 2 R**SO 2 —
3ab
—N(R)SO 2 R*SO 2 N(R)OC(O)R**OC(O)—
3ac
—N(R)SO 2 R*SO 2 N(R)P(OR)(O)R**P(O)(OR)—
3ad
—N(R)SO 2 R*SO 2 N(R)P(OR)OR**OP(O)(OR)—
3ae
—N(R)SO 2 R*SO 2 N(R)C(O)—
3af
—N(R)SO 2 R*SO 2 N(R)C(O)NHR**NHC(O)—
3ag
—N(RSO 2 )R*N(RSO 2 )C(O)R**C(O)—
3ba
—N(RSO 2 )R*N(RSO 2 )SO 2 R**SO 2 —
3bb
—N(RSO 2 )R*N(RSO 2 )C(O)OR**OC(O)—
3bc
—N(RSO 2 )R*N(RSO 2 )P(O)(OR)R**P(O)(OR)—
3bd
—N(RSO 2 )R*N(RSO 2 )P(O)(OR)OR**OP(O)(OR)—
3be
—N(RSO 2 )R*N(RSO 2 )C(O)—
3bf
—N(RSO 2 )R*N(RSO 2 )C(O)N(H)R**N(H)C(O)—
3bg
DETAILED DESCRIPTION OF THE INVENTION
The synthesis of N,N*-disubstituted disulfonamides may be achieved from either the reaction of 2 equivalents of a mono substituted amine with a disulfonyl dichloride or by the reaction of 2 equivalents of a sulfonyl chloride with an equivalent of a primary amine as illustrated in the equations below:
2CH 3 SO 2 Cl+NH 2 CH 2 CH 2 NH 2 →CH 3 SO 2 N(H)CH 2 CH 2 N(H)SO 2 CH 3
2CH 3 NH 2 +C 6 H 4 (SO 2 Cl) 2 →C 6 H 4 SO 2 NHCH 3 ) 2
The preparation of the sulfonamides and sulfonyl chlorides employed in the present invention has been reviewed in the literature (The Chemistry of Sulfonic Acids, Esters and their Derivatives, Chapter 10; Preparation of Sulfonic Acids, Esters, Amides and Halides by J. Doyle, John Wiley & Sons 1991). The preparation of the sulfonamides is further illustrated in my copending application Ser. No. 11/012,829 filed Dec. 15, 2004 published as US 20060128978. The utilization of N,N*-disubstituted disulfonamides for the synthesis of hydroxy functional (ether sulfonamides) as thermoplastic barrier resins has been reported (U.S. Pat. No. 5,149,768).
The polymer-forming chemistry of the present invention, i.e., the chemical transformation of a substituted sulfonamide with either an acid chloride or isocyanate to form a chemical moiety that is the linking unit of the condensation polymer is described and illustrated in Examples 1–6. N-Methyl-4-methylbenzene sulfonamide was utilized as the “model” sulfonamide for the reaction of the acid chlorides/isocyanates to define the repeating functional moiety of the polymers. Several of the model substrates were prepared under thermal conditions, that is by heating the reactants in a high boiling solvent such as 1,2-dichlorobenzene to eliminate hydrochloric acid and also achieve the addition of the sulfonamide to the isocyanate. The alternative procedure involves generating the disodium salt of the disulfonamide followed by the addition of the acid chloride. The examples of the polymer preparation were carried out by generating the disodium salt followed by the addition of the acid chloride or in the case of the isocyanate by using a basic catalyst (e.g., a tertiary organic amine). Interfacial processes utilized for the production of polycarbonates can also form the condensation polymers of the present invention.
The following are some examples of N,N*-substituted disulfonamides used in the present invention: N,N*-dimethyl-1,3-benzene disulfonamide, N,N*-dicyclohexyl-2,5-dimethylbenzene disulfonamide, N,N*-diethyl-2,6-naphthalene disulfonamide, N,N*-dibutoxyethyl-2,6-naphthalene disulfonamide, N,N*-diethyl-4,4*-phenyl ether disulfonamide, N,N*-bis(methylsulfonyl)-1,8-diaminooctane, N,N*-bis(methylsulfonyl)-1,5-diaminonaphthalene.
The following are some examples of dicarboxylic acid dichlorides used in the present invention: succinyl chloride, adipoyl chloride, 1,3-phthalic dichloride, 4,4*-phenyl ether dicarboxylic acid dichloride, 4,4*-biphenyl ether dicarboxylic dichloride, and 1,8-octane dicarboxylic acid dichloride.
The following are some examples of disulfonic acid dichlorides used in the present invention: 1,3-benzene disulfonyl dichloride, 2,5-diethyl-1,3-benzene disulfonyl dichloride, 4,4*-phenyl ether disulfonyl dichloride, 4,4*-biphenyl disulfonyl dichloride, 1,10-decane disulfonic acid dichloride. The following are examples of bis chloroformates of the present invention but not limited to: diethylene glycol bischloroformate, diethyl glycol bischloroformate, 4,4*-dihydroxybiphenyl bischloroformate, 2,6-dihydroxynaphthalene bischloroformate, 4,4*-dihydroxybenzophenone bischloroformate, 4,4*-dihydroxyphenyl sulfone bischloroformate.
The following are some examples of bis phosphoryl chlorides used in the present invention: 1,4*-butanediol bisethoxy phosphoryl chloride, diethylene glycol bis methoxy phosphoryl chloride, 4-hydoxyphenyl sulfone ethoxy phosphoryl chloride.
The following are some examples of bis phosphonyl chlorides used in the present invention: 1,6-hexane bismethoxy phosphonyl chloride, 1,10-decane bisphenoxy phosphonyl chloride.
The following are some examples of the diisocyanates used in the present invention: 1,3-diisocyanatopropane, 1,10-diisocyanatodecane, 1,3-phenylene-diisocyanate, 1,5-naphthalene-diisocyanate, 4-isocyanato phenyl ether.
The following Examples 1–6 are model reaction examples given to illustrate the invention and should not be construed as limiting its scope.
EXAMPLE 1
N-Methyl-4-methylbenzene sulfonamide (3.70 g, 0.02 mol) and 4-methylbenzoyl chloride (3.08 g, 0.02 mol) were dissolved in xylene and refluxed for 72 hrs. After evaporation of the xylene, the residue was dissolved in ethyl acetate and washed with dilute sodium carbonate solution. After separation, drying over anhydrous magnesium sulfate and evaporation of the solvent in vacuo, the residue was recrystallized from hexane-ethyl acetate to give N-4-methylbenzoyl-N*-methyl-4-methylbenzene sulfonamide mp 90–92° C. MS m/z 303. (M+ calcd for C 16 H 17 NO 3 S=303). H NMR (300 Mhz, CDCl 3 ) d 2.30 (s, 3, CH 3 ), 2.46 (s, 3, CH 3 ), 7.21 (m, 2, aromatic), 7.35 (m, 2, aromatic), 7.49 (m, 2, aromatic), 7.84 (m, 2, aromatic).
EXAMPLE 2
4-Methylbenzenesulfonyl chloride (3.80 g, 0.02 mol) and N-methyl-4-methylbenzene sulfonamide (3.70 g, 0.02 mol) were added to 1,2-dichlorobenzene (50 ml) and the solution refluxed for 48 hrs. The solvent was evaporated in vacuo and the residue recrystallized from hexane-acetone to give N*-methyl-N*-4-methylphenysulfonyl-4-methylbenzene sulfonamide mp 109–111° C. MS m/z 339. (M+ calcd for C 15 H 17 NO 4 S=339). H NMR (300 Mhz, CDCl 3 ) d 2.43 (s, 6, CH3), 3.25 (s, 3, NCH 3 ), 7.34 (m, 4, aromatic), 7.88 (m, 4, aromatic).
EXAMPLE 3
Phenyl chloroformate (1.57 g, 0.01 mol) and N-methyl-4-methylbenzene sulfonamide (1.85 g, 0.01 mol) were diluted with 1,2-dichlorobenzene (15 ml) and refluxed for 40 hrs. The solvent was evaporated in vacuo and the residue diluted dichloromethane and the dichloromethane washed with water (2×), dried over anhydrous magnesium sulfate. Evaporation of the solvent in vacuo gave N-methyl-N*-phenoxycarbonyl-4-methylbenzene sulfonamide mp 98–100° C. MS m/z 305. (M+ calcd for C 15 H 15 NO 4 S=305). H NMR (300 MHz, CDCl 3 ) d 2.43 (s, 3, CH 3 ), 2.45 (s, 3, NCH 3 ), 6.95 (m, 2, aromatic), 7.18–7.35 (m, 5, aromatic), 7.88 (m, 5, aromatic).
EXAMPLE 4
N-methyl-4-methylbenzene sulfonamide (4.65 g, 0.025 mol) was dissolved in toluene. Tetraethyl ammonium chloride (50 mg) and 50% sodium hydroxide were added to the solution. The reaction flask was fitted with a Dean & Stark apparatus and the solution refluxed for 2 hrs and diethyl phosphoryl chloride (4.31 g, 0.025 mol) was added to the reaction mixture and stirring continued for 2 hrs. After filtration of solids, the solvent was evaporated in vacuo to give N-methyl-N*-4-methylphenylsulfonyl diethyl phosphoramide. MS m/z 276 (M+ minus OCH 2 CH 3 ). (M+ calcd for C 12 H 20 NO 5 PS=321. H NMR (300 Mhz, CDCl 3 ) d (1.41 (m, 6, CH 3 ), 2.43 (s, 3, CH 3 ), 3.06 (d, 2, NCH 3 ), 4.20 (m, 4, CH 2 ), 7.31 (m, 2, aromatic), 7.87 (m, 2, aromatic).
EXAMPLE 5
N-Methyl-4-methylbenzene sulfonamide (3.70 g, 0.02 mol) was dissolved in dichloromethane (65 ml). Tetraethyl ammonium chloride (75 mg) and 50% sodium hydroxide (1.60 g) were added to the dichloromethane solution and the solution stirred at room temperature for 1 hr. Triphosgene (1 g) was diluted with dichloromethane (20 ml) and added dropwise the solution. The solids dissolved during the reaction. The dichloromethane solution was washed with water (2×) and dilute potassium carbonate and dried over anhydrous potassium carbonate. Evaporation of the solvent in vacuo gave 3.5 g of N-methyl-N*-(4-methylbenzenesulfonyl urea). MS m/z 332 (M+ minus SO 2 ) (M+ calcd for C 11 H 15 NO 3 S=396). H NMR (300 Mhz, CDCl 3 ) d 2.45 (s, 3, CH 3 ), 3.16 (s, 3, NCH 3 ), 7.32 (m, 2, aromatic), 7.76 (m, 2, aromatic).
EXAMPLE 6
Phenyl isocyanate (1.19 g, 0.01 mol) and N-methyl-4-methylbenzene sulfonamide (1.85 g, 0.01 mol) were dissolved in 1,2-dichlorobenzene (20 ml) and refluxed for 40 hrs. After cooling, the solvent was evaporated in vacuo to give a viscous oil that crystallized on standing to give N-methyl-N-4-methylphenyl-N*-phenyl urea mp 63–65° C. MS m/z 304. (M+ calcd for C 15 H 16 N 2 O 3 S=304). H NMR (300 Mhz, CDCl 3 ) d 2.43 (s, 3, CH 3 ), 2.65 (s, 3, CH 3 ), 7.33 (m, 5, aromatic), 7.48 (m, 1, aromatic), 7.75 (m, 3, aromatic).
The following examples illustrate the formation of the polymers of the present invention but are not intended to be limiting.
EXAMPLE 7
POLYMERIZATION OF N,N*-BIS-4-METHYLBENZENESULFONYL ETHYLENE DIAMINE AND ADIPOYL CHOLRIDE
N,N*-bis-4-methylbenzenesulfonyl ethylene diamine was prepared from ethylene diamine and 4-methylbenzenesulfonyl chloride and recrystallized from aqueous methanol mp 160–162° C. The disulfonamide (1.49 g, 0.004 mol) was dissolved in dichloromethane (60 ml). Tetraethyl ammonium chloride and 50% sodium hydroxide (0.64 g) were added to the solution. The reaction mixture was stirred for 1 hr to form the sodium salt, then the adipoyl chloride (0.73 g, 0.064 mol) was diluted with dichloromethane (20 ml) and added dropwise to the solution over 20 min. After 2 hr, the dichloromethane solution was washed with water (2×), dilute potassium carbonate and dried over anhydrous potassium carbonate and the solution evaporated in vacuo to give a white solid mp 90–110° C. The absence of an NH band in the IR spectrum and the presence of a carbonyl band at 1698 cm −1 were in agreement with the polymer structure.
EXAMPLE 8
POLMERIZATION OF N,N* BIS-4-METHYLBENZENESULFONYL ETHYLENE DIAMINE AND 4,4*-PHENYL ETHER DISULFONYL DICHLORIDE
N,N*-Bis-4-methylbenzenesulfonyl ethylene diamine (1.10 g, 0.003 mol) was dissolved in dichloromethane (60 ml). Tetraethyl ammonium chloride (50 mg) and 50% sodium hydroxide (48 g) were added to the solution. The reaction was stirred for 1 hr to form the disodium salt, then 4,4*-phenyl ether disulfonyl dichloride (1.10 g, 0.003 mol) in dichloromethane (20 ml) was added dropwise to the solution at room temperature with the disappearance of the slurry. After 2 hrs, the dichloromethane solution was washed with water (2×), dilute potassium carbonate and the solution dried over anhydrous potassium carbonate. The solvent was evaporated in vacuo to give a white solid mp >290° C. The absence of the NH band of the diimide in the IR spectrum was in agreement with the theoretical polymer structure. The melting point indicates a thermoplastic resin that can be injection molded or extruded into useful shapes.
EXAMPLE 9
POLMERIZATION OF N,N*-BIS-4-METHYLBENZENESULFONYL ETHYLENE DIIAMINE AND 2,4-DIISOCYANTOTOLUENE
N,N*-Bis-4-methylbenzenesulfonyl ethylene diamine (1.84 g, 0.05 mol) and 2,4-diisocyanatotoluene (0.87 g, 0.005 mol) were diluted with dichloromethane (10 ml). Tetrahydrofuran (10 ml) was added to completely dissolve the diimide. Triethylamine (50 mg) was added and the solution stirred overnight at room temperature. The solvent and catalyst were removed in vacuo to give a white solid mp 95–110° C. The IR spectrum had and NH band at 3293 cm −1 and a strong carbonyl band at 1713 cm −1 . The disappearance of the very strong isocyanate band at 2270 cm-1 was also in agreement with the polymer structure. | The present invention relates to novel condensation polymers where N,N*-disubstituted disulfonamides are copolymerized with an organic acid dihalide such as dicarboxylic acid dichlorides, disulfonic acid dichlorides, bis chloroformates, diphosphoryl acid dichlorides, diphosphonyl acid dichlorides, or phosgene or with diisocyanates. The polymers obtained are thermoplastic and useful in molding and extrusion application. | 2 |
NOTICE REGARDING COPYRIGHTED MATERIAL
[0001] A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction of the patent document or the patent disclosure as it appears in the Patent and Trademark Office file or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
[0002] This invention relates to vehicle diagnostics.
BACKGROUND OF THE INVENTION
[0003] The current art of extracting raw data from a vehicle and converting it to engineering units is based on a one to one extraction of the data from the vehicle's bus messages and applying a linear scaling function. This conversion can be processed either in the diagnostic device or transmitted to a centralized host computer for conversion.
SUMMARY OF INVENTION
[0004] This invention extends the ability to process raw data to human understandable data values within a vehicle diagnostic computer to allow the user to create new data values from multiple raw data sources without depending on preprogrammed functions or resorting to reprogramming the basic software of the device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] A better understanding of the present invention can be obtained when the following detailed description of the preferred embodiment is considered in conjunction with the following drawings, in which:
[0006] FIG. 1 is a diagram that explains the combination of data sources and flow of data.
DETAILED DESCRIPTION
[0007] An engine (or electronic) control unit (ECU) determines the amount of fuel, ignition timing and other parameters of a vehicle engine by reading values from sensors monitoring the engine and other, associated vehicle components and (sub)systems (including those involving telematics). In particular, to use an exemplary standard, a vehicle can be determined by requesting a list of supported Parameter IDs (PIDs), as defined in OBDII/SAE J1979.
[0008] Conventional implementation of configuring for processing data allowed the user to extract the raw data from a specific location within a string of bits from a serially transmitted message from a vehicle's diagnostic message in raw or native format; and to ‘scale’ raw data to convert to desired engineering units by the linear formula of “mx+b” where ‘m’ and ‘b’ are configurable parameters. The result is that the raw data could be converted to the desired engineering units for any data point. This conversion, in particular, and many other functions, are conventionally provided by internal hard-coded firmware in the vehicle diagnostic device.
[0009] In contrast to conventional methods, a more flexible and user-convenient method is disclosed by the present invention. The present invention may be implemented in the vehicle telematics locator unit as a matter of convenience (so that, for example hardware and software resources may be shared with the telematics technology and so that the results of the present invention may be sent to a central intelligence, or may receive over-the-air commands from a central intelligence). For convenience, the present invention will be described as residing in the vehicle Locator but it will be appreciated that the present invention does not depend on the presence and absence of telematics technology, or on the exact physical location within the vehicle of the physical implementation of the present invention. The present invention can be implemented as a stand-alone unit interfacing with the ECU or equivalent sources of monitored PIDs.
[0010] With reference to FIG. 1 , Raw ECU message 100 has data in its native (or near-native) form from the ECU. Derived Data 110 is raw ECU message that has already been processed so that relevant information is presented for easy reading. The user configures the Locator to chose which one of {Raw ECU message 100 and Derived Data 110 } to use as Primary Data 200 (and if Raw ECU message 100 is chosen, it will be processed before forming part of Primary Data 200 ).
[0011] The user also configures the Locator to choose additional Derived Data 120 to form Secondary Data 300 .
[0012] Thus two sources are defined, Primary Data 200 and Secondary Data 300 .
[0013] The User configures the Locator to choose one of several methods to further process Primary Data 200 . One conventional method is by an internal hard-coded function 401 which then produces Derived Data 480 . Another conventional method is to process linearly Primary Data 200 , i.e. multiply by a scaling factor or scalar and then add offset—step 400 . A new method is by External Function 450 (which will be explained later below) which then produces Derived Data 480 .
[0014] The User may configure that, in Step 470 , the result of Step 400 (multiply by a scaling factor and then add offset) is processed in conjunction with Secondary Data 300 , and the result of Step 470 becomes Derived Data 480 . In Step 470 , the interaction between Secondary Data 300 and the result of Step 400 , is defined by the user choice of a common arithmetic operator (as will be explained below).
[0015] FIG. 1 shows the configurable mathematical options:
[0000] DerivedData 480=(Scaling*[Location within message of Raw Data]+Offset)<*or+or−or/or 0*>SecondaryData 380)
[0000] OR (External Function 450 using scripting Language (Primary Data, Secondary Data)
[0000] OR (Internal hardcoded Function 401 (Primary Data, Secondary Data).
[0016] An exemplary format of a user-configurable command to define a conventional PID, is:
[0017] [<serviceName>define<description><PID><byteloc>:<bitloc><length><m_scaling factor><b_offset><unitsLabel>]
[0018] The invention allows additional parameters to be included in the command that, for example, transforms a single variable linear equation to a multivariable equation to create a new valued PID based on multiple variables operating (perhaps operating on each other) to transform the output variable to a new entity.
[0019] Each definition command of the present invention's new configuration command, allows two more fields: 1) an arithmetic operator field that will hold a value representing one of {multiplication, addition, subtraction or division}; and 2) an operand being a secondary data source, being a pre-defined PID. Accordingly, according to the present invention, the format of a user-configurable command to define a Derived PID is:
[0020] [<serviceName>define<description><PID><byteloc>:<bitloc><length><m_scaling factor><b_offset><unitsLabel><operator><operand>]
[0021] In its most basic form, the format of a user-configurable command to define a Derived PID is:
[0022] [<serviceName>define<description><primary data source><operator><operand=secondary source of data>]
[0023] where <operator> is any function recognized by mathematics and (however) implemented by mathematics and <operand=secondary source of data> is any other PID (whether pre-existing according to industry standards or another user-defined Derived PID).
[0024] Below is an example to calculate Fuel Economy in Litres/100 Kms where the available PIDs are MAF (mass air flow) and Speed in km/hr.
[0000] The equation for Fuel Economy=FuelRate {litres/hr}/Speed {km/hr}*100→{litres/100 km}
[0025] FuelRate is calculated as follows.
[0000] FuelRate=MAF*(3600{secs/hr})/(1000{cc/litres}* AirFuelRatio*gasoline density)
[0026] An example of the command for defining Speed (according to the above command format) as an exemplary Secondary Data 300 ) is:
[0027] [<J1979>define<speed><1-D><3:1><8><1><0><km/hr>]
[0028] Thus PID 1-D holds the value for speed.
[0029] Next is the command to use this secondary source in the formula to transform MAF and Speed into Fuel Economy (where scaling m=0.356=3600/1000*13.7*0.737{density:kg/L}:
[0030] [<J1979 define<fuelEconomy><99-85><3:1><8><0.356><0><L/100 kms></><1-D>]
[0031] Thus (user-defined) Derived PID 99-85 holds the value for Fuel Economy. This PID can be read by another (user-configured PID, created by the same method described herein) or sent upstream to central intelligence.
[0032] The operator in the above example is “/” (division) and the Secondary Data 300 is PID 1-D which has been calculated above. In other words, user-defined Derived PID 99-85 transforms MFA and Speed into Fuel Economy by arithmetically processing Primary 200 and Secondary Data 300 .
[0033] The benefits of the present invention include: the ability to create arbitrary functions; simplification of the built-in functions and their selection, so that, for example, fuel economy could be expected to be available but to supply conversions for all the methods of displaying fuel economy, the system would otherwise have to be preprogrammed for miles/gallon, km/litre or litre/100 kms; and if these two PIDs are not available, fuel economy may have to be calculated from completely different sources (such as the dwell time of the injector pulses that have very different transforming equations).
[0034] External Function.
[0035] The concept of the external function feature is to provide a method for the PID processing code to determine if a PID is connected to an externally processed computation, and then provide the interface hooks to send the captured data to that external code and then to retrieve the results for further processing and/or storage.
[0036] The following pseudo code shows how the external function is initiated. The external function can be expressed using any standard or custom programming language that can be executed within the telematics computing device.
[0000]
While( PidRecord = getNextPid( ) ) != endofPidList)
{
if( externalFunctionName = CheckForExternalFunction( ) !=
NULL)
{
PrimaryData = PidRecord.getValue( );
SecondaryData = PidRecord.getSecondaryValue( );
newPrimaryData = ExternalFunctionHandoff(
externalFunctionName, PrimaryData, SecondaryData);
PidRecord.setValue( newPrimaryData );
}
//...continue processing by checking for internal configuration
}
[0037] The ‘CheckForExternalFunction’ function simply parses the definitions of the PIDs and determines if it has been configured to interact with an external function (relative to the program that is asking). The specific expression used to apply the external function, is to insert a “flag” or similar marker (when parsing)—for example, a “@” character as the first character in the <description> field of the user-configured Derived PID definition record. The remaining characters are the alphanumeric name that identifies the external function in the external programming application, and control is thereby passed accordingly.
[0038] The ‘External Function Handoff’ function is an interface routine that passes the name of the function and any number of internally obtained data values to the another program running in the computer. This other program will then return the value after having executed any arbitrary sequence of computer code crafted by a programmer.
[0039] Herein, the term “primary” and “secondary” are used only in the numerical counting sense (of “first” and “second”) and without necessarily connoting any sense of the relative “importance” of the respective data they enumerate.
[0040] It will be appreciated that one of Primary Data 200 or Secondary Data 300 is or could be itself a PID that is the result of a prior application of the present invention (i.e. is Derived Data 110 or Derived Data 120 ).
[0041] It will be appreciated that the result may be treated as a PID that other PID-defining functions can read and use, or may be simply forwarded to central intelligence for further processing.
[0042] It will be appreciated by those skilled in the art that this invention can be continued with a “tertiary” (or third) data (i.e. the resulting PID is the result of processing three pieces of data).
[0043] Thus, it is seen that user creates the equation for derived data points rather than limited to a selection of prior programmed functions.
[0044] The significance of this invention is that it allows the user to create a custom algorithm from a simple set of operations without having to resort to programming languages. It allows the user to remain as a domain expert without requiring him to be a programming expert.
[0045] Allow more than two input data points in each configurable function. This will reduce the intermediate data point requirements and be easier to create more complex functions
[0046] Instead of having the user configure the functions through configuration commands, the user may use external scripting languages to process the input data points to obtain the derived data point value.
[0047] It will be appreciated that arithmetic operators other than the conventional {addition, subtraction, multiplication, division) are possible and advisable depending on the application (e.g. pick the largest of the absolute value of processed Primary Data 200 and Secondary Data 300 ). Thus, for example, the configurable operator could be more complex mathematical functions such as Square Root functions, Power Functions, Logarithmic functions, and complex Table lookup functions, fuzzy logic tables, whether such functions are accessed directly or indirectly on the operand.
[0048] Accordingly, depending on the nature of the operator (arithmetic or more complex), the nature of the operand will be defined in alignment (semantically and physically to model the realities of the engine and associated vehicle components).
[0049] Provide Scaling Functionality (conversion to engineering units) for the secondary data point so that two raw data points could be used in the same configured function.
[0050] Although the method and apparatus of the present invention has been described in connection with the preferred embodiment, it is not intended to be limited to the specific form set forth herein, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents, as can be reasonably included within the spirit and scope of the invention as defined by the appended claims. All figures are drawn for ease of explanation of the basic teachings of the present invention only; the extensions of the figures with respect to number, position, relationship, and dimensions of the parts to form the preferred embodiment will be explained or will be within the skill of the art after the following teachings of the present invention have been read and understood. Further, the exact dimensions and dimensional proportions to conform to specific force, weight, strength, and similar requirements will likewise be within the skill of the art after the following teachings of the present invention have been read and understood. | The user configures to process at least two data sources without depending on preprogrammed functions or resorting to reprogramming the basic software of the device. | 6 |
FIELD OF THE INVENTION
The present invention generally relates to the separation of gas from a gas-liquid two phase flow stream. More specifically, it relates to directionally shaping the gas-liquid two phase flow stream so that the majority of the gas is located in a certain area of the flow stream, which allows effective separation of the gas and the liquid.
BACKGROUND OF THE INVENTION
A gas-liquid two phase flow stream includes a mixture of different fluids having different phases, such as air and water, steam and water, or oil and natural gas. A gas-liquid two phase flow takes many different forms and may be classified into various types of gas distribution within the liquid. These classifications are commonly called flow regimes or flow patterns and are illustrated in FIGS. 1A-1E . Bubble flow as illustrated in FIG. 1A is typically a continuous distribution of liquid with a fairly even dispersion of bubbles in the liquid. Slug or plug flow as illustrated in FIG. 1B is a transition from bubble flow where the bubbles have coalesced into larger bubbles with a size approaching the diameter of the tube. Churn flow as illustrated in FIG. 1C is a pattern where the slug flow bubbles have connected to one another. In annular flow as illustrated in FIG. 1D , liquid flows on the wall of the tube as a film and the gas flows along the center of the tube. Finally, in wispy annular flow as illustrated in FIG. 1E , as the liquid flow rate is increased, the concentration of drops in the gas core increases, leading to the formation of large lumps or streaks of liquid.
It is often desirable to separate the gas and liquid components of a fluid from one another to enable proper operation of systems, such as certain types of liquid pumps. Conventional vertical or horizontal gas-liquid separators are available to separate gas from liquid. Conventional separators typically employ mechanical structures, wherein an incoming fluid strikes a diverting baffle which initiates primary separation between the gas and liquid components. Mesh pads or demister pads are then used to further remove suspended liquid. The sizing of a separator and the particular characteristics of the separator is dependent upon many factors, which may include, the flow rate of the liquid, the liquid density, the vapor density, the vapor velocity, and inlet pressure. Vertical separators are typically selected when the vapor/liquid ratio is high or the total flow rate is low. Horizontal separators are typically preferred for low vapor/liquid ratio or for large volumes of total fluid.
One application of these types of separators is in oil and gas drilling operations. Specifically, a mud-gas separator is used when a kick is experienced in a wellbore during drilling operations. A kick is the flow of formation fluids into the wellbore during drilling operations. If a kick is not quickly controlled, it can lead to a blow out. As part of the process for controlling a kick, the blow-out preventors are activated to close the wellbore and wellbore fluids are slowly circulated out of the wellbore while heavier drilling fluids are pumped into the wellbore. A mud gas separator is used to separate natural gas from drilling fluid as the wellbore fluid is circulated out of the wellbore. Often times, however, prior act separators, including mud-gas separators, cannot keep up with the flow rate from the wellbore.
Of course, separators are also used in the production of oil and gas to separate natural gas out of the oil that is being produced. Additionally, there are many other applications that require the use of gas-liquid separators.
SUMMARY OF THE INVENTION
This invention relates to directionally shaping two-phase mixed flow in a curved path within a flow shaping line prior to introduction into a separator so as to enhance operation of the separator. Shaping the two-phase flow in a curvilinear path will allow centrifugal force to more readily force the heavier, denser liquid to the outside wall of the flow shaping line in the curved path and allow the lighter, less dense vapor or gas to occupy the inner wall of the flow shaping line. Once the gas is fairly well positioned on the inner wall of the flow shaping line, an exit port located on the inner wall will allow for the majority, if not all, of the gas, along with a low amount of liquid, to be sent to a conventional separator. A very high ratio of vapor/liquid at a flow rate much lower than the total flow rate within the flow shaping line is then sent to the conventional separator. This allows for efficient separation of the vapor from the liquid with the use of a smaller, more economical conventional separator than what would have been required for the full flow rate.
Additionally, a fluid guiding surface may be placed on the inner wall of the flow shaping line at the exit port to further aid in directing the gas to flow to the conventional separator. Furthermore, the liquid return from the conventional separator may be arranged in close downstream proximity to the exit port on the inner wall of the flow shaping line. The close proximity of the liquid return and the exit port allows the use of a venturi, nozzle or other restriction located adjacent the liquid return in the flow shaping line just downstream of the exit port. The venturi, nozzle or other restriction accelerates the velocity of the liquid in flow shaping line as it flows across the exit port. This acceleration of the liquid helps to pull the liquid out of the conventional gas-liquid separator. In addition, the acceleration of the liquid within the flow shaping line helps to prevent any solids that may be present in the gas-liquid flow from entering the exit port and it helps to lower the amount of liquid that enters the exit port and thus enters the conventional separator.
The invention therefore allows a gas-liquid fluid to be effectively separated with the use of a smaller conventional separator than was previously possible. The invention accomplishes this without using additional complex mechanical devices and thus will operate efficiently and reliably.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present disclosure and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying figures, wherein:
FIGS. 1A-1E illustrate a cross-sectional view of various flow regimes of two phase gas-liquid flow.
FIG. 2 illustrates a cross-sectional view of an embodiment of separation apparatus.
FIG. 3 illustrates a cross-sectional view of the embodiment of the separation apparatus in FIG. 2 taken across line 3 - 3 .
FIG. 4 illustrates a cross-sectional view of another embodiment of a separation apparatus with two flow shaping loops.
FIG. 5 illustrates a cross-sectional view of another embodiment of a separation apparatus where the diameter of the flow shaping line is less than the diameter of the main line.
FIG. 6 illustrates a cross-sectional view of another embodiment of a separation apparatus where the flow shaping line forms a generally elliptical shape.
FIG. 7 illustrates a cross-sectional view of another embodiment of a separation apparatus with two exit ports.
FIG. 8 illustrates a cross-sectional view of another embodiment of an exit port in a separation apparatus.
FIG. 9 illustrates a cross-sectional view of another embodiment of an exit port with an airfoil shape located away from the inner wall in an embodiment of a separation apparatus.
FIG. 10 illustrates a cross-sectional view of another embodiment of a separation apparatus located near the seabed in an oil and gas drilling operation.
DETAILED DESCRIPTION
In the detailed description of the invention, like numerals are employed to designate like parts throughout. Various items of equipment, such as pipes, valves, pumps, fasteners, fittings, etc., may be omitted to simplify the description. However, those skilled in the art will realize that such conventional equipment can be employed as desired.
FIG. 2 illustrates a cross-sectional view of an embodiment of a separation apparatus 10 . In an exemplary embodiment, the separation apparatus 10 includes a gas-liquid flow 12 traveling in a vertical direction 14 in a main line 15 . The gas-liquid flow 12 could be any type of multiphase gas-liquid flow regime or flow pattern, such as, for example, bubble flow, slug or plug flow, churn flow, annular flow or wispy annular flow. The gas-liquid flow 12 within main line 15 is directed into a circular flow path 16 in a flow shaping line 17 . The circular flow path 16 of flow shaping line 17 creates an increased distribution of the gas on inner wall 24 of the flow shaping line 17 . The increased distribution of the gas on the inner wall 24 of the flow shaping line 17 results in part by the relatively heavier and denser liquid 18 of flow 12 being forced to the outer wall 20 of the flow shaping line 17 due to centrifugal force of circular flow path 16 , while the lighter gas 22 is driven to the inner wall 24 . In an embodiment with a vertical or partly vertical orientation of the flow shaping line 17 , gravitational effects may also aid in increasing the distribution of the gas on the inner wall 24 of the flow shaping line 17 . In an embodiment, a transition section 13 between the main line 15 and flow shaping line 17 may be provided with a shape as illustrated to further aid in creating the increased distribution of the gas on inner wall 24 of the flow shaping line 17 .
As the gas-liquid flow 12 continues to travel through the circular flow path 16 of flow shaping line 17 , the gas-liquid flow 12 forms a flow path that exhibits a high concentration of the gas 22 on the inner wall 24 of the flow shaping line 17 . In the embodiment shown in FIG. 2 , at location 26 , which is approximately 315 degrees around shaping line 17 (or 45 degrees from the vertical), the separation of gas 22 from liquid 18 has reached a degree that gas 22 primarily occupies the space adjacent the inner wall 24 of the flow shaping line 17 . As seen in FIG. 3 , which is a cross section 3 - 3 of the flow shaping line 17 and gas-liquid flow 12 at location 26 , the gas 22 occupies mainly the inner wall 24 of the circular flow path 16 of the flow shaping line 17 .
With gas-liquid flow 12 forming a more stratified flow regime, or at least the distribution or volume of gas near the inner wall 24 of the flow shaping line 17 has increased at the point of location 26 , the gas 22 may now be effectively bled off from the gas-liquid flow 12 at an outlet port 28 positioned on the inner wall 24 of the flow shaping line 17 . Although outlet port 28 may be positioned any where along flow path 16 , it is preferably selected to be at a point where substantial separation of gas from liquid has occurred. Thus, in one preferred embodiment, the outlet port 28 is downstream of location 26 . At about a location 26 , which is approximately at an angle of approximately 45 degrees from the vertical 74 , it has been found that the concentration, separation or stratification of the gas 22 from the liquid 18 is at a point that gas 22 occupies a greater volume of space adjacent the inner wall 24 of the main line 15 than liquid 18 . In other embodiments, the outlet port 28 may be located between generally 45 degrees from the vertical and generally zero degrees with the vertical. While location 26 is illustrated at approximately 315 degrees around flow shaping line 17 and has been found to be a point where a substantial volume of gas has been driven to inner wall 24 , location 26 is used for illustrative purposes only.
In an exemplary embodiment, a fluid guiding surface 30 is located on the inside diameter 32 of the inner wall 24 of the flow shaping line 17 upstream of the outlet port 28 . The fluid guiding surface 30 includes a downstream end 36 that curves around the corner 37 located at the junction of the outlet port 28 and the flow shaping line 17 . In one embodiment, the fluid guiding surface 30 may comprise at least a partial airfoil or hydrofoil shape. The fluid guiding surface 30 functions to guide the gas 22 into the outlet port 28 . The gas 22 follows the contour of the fluid guiding surface 30 and the gas 22 will follow the curve of the downstream end 36 into the outlet port 28 .
An amount of liquid 18 from the gas-liquid flow 12 will also be carried into the outlet port 28 thus forming a new gas-liquid flow 40 which includes a much lower percentage of liquid compared to the gas-liquid flow 12 . The new gas-liquid flow 40 from outlet port 28 is then directed into a conventional gas-liquid separator 38 , as shown in FIG. 2 , for further separation of the gas and liquid. Outlet port 28 is connected to the conventional gas-liquid separator by separator inlet line 33 . The gas-liquid separator 38 contains a gas exit 39 to allow for the removal of the gas 22 separated from the new gas-liquid flow 40 . The gas-liquid separator 38 also contains a liquid exit 41 that is connected to liquid inlet port 42 in a return line 43 by a separator liquid exit line 44 . The return line 43 is formed at the end of, and is fluidicly connected to, the flow shaping line 17 . Those skilled in the art will appreciate that separation apparatus 10 is shown as integrated with gas liquid separator 38 , but can be a completely separate structure.
In an exemplary embodiment, the liquid inlet port 42 in the return line 43 is in close downstream proximity to outlet port 28 of the flow shaping line 17 . The close proximity of the liquid inlet port 42 and the outlet port 28 allows the use of a venturi 46 located adjacent the liquid inlet port 42 in the return line 43 . The venturi 46 accelerates the velocity of the liquid 18 in return line 43 as it flows across the liquid inlet port 42 . This acceleration of liquid 18 helps to draw the liquid out of the conventional gas-liquid separator 38 . In addition, the acceleration of the liquid 18 within return line 43 facilitates separation of gas from liquid within flow shaping line 17 , minimizes the likelihood that any solids present in the gas-liquid flow 12 will enter outlet port 28 , and minimizes the amount of liquid 18 that enters the outlet port 28 .
It has been observed that the liquid flow rate entering the outlet port 28 in the new gas-liquid flow 40 is approximately twenty percent of the of the flow rate of the gas-liquid flow 12 that is in the flow shaping line 17 upstream of the outlet port 28 . The new gas liquid flow 40 contains a higher percentage of the gas 22 than was in the gas-liquid flow 12 , but with much lower amount of liquid 18 in the flow. This provides a very efficient first step in the separation of the gas 22 from the liquid 18 without the use of additional pumps, valves or other mechanical equipment.
This efficient first step in the separation of the gas 22 from the liquid 18 is provided at least in part by one or more aspects of the invention. First, the use of the circular flow path 16 to centrifugally increase the concentration of the gas 22 on the inner wall 24 of the flow shaping line 17 . Second is the fluid guiding surface 30 used to direct the gas 22 into the outlet port 28 . Third, venturi 46 accelerates the velocity of the liquid 18 as it flows past the outlet port 28 , thereby functioning to lower the amount of liquid 18 that enters the outlet port 28 and minimize entry of solids into outlet port 28 . The venturi 46 also lowers the pressure of the liquid 18 at the liquid inlet port 42 of the return line 43 , which draws the liquid 18 out of the conventional gas-liquid separator 38 .
As mentioned above, the efficient first step in the separation of the gas 22 from the liquid 18 significantly decreases the amount of liquid 18 entering the conventional gas-liquid separator 38 . This allows for the use of much smaller size conventional gas-liquid separators than would have previously been possible for a given flow rate.
While circular flow path 16 is shown as positioned in a vertical plane, in another embodiment the circular flow path 16 could be in a horizontal plane or in a plane with an inclination between horizontal and vertical.
In another embodiment, illustrated in FIG. 4 , the circular flow path 16 could be replicated in multiple loops 78 to develop the increased concentration of the gas 22 on the inner wall 24 of the flow shaping line 17 . In another embodiment as seen in FIG. 5 , the flow shaping line 17 may be formed with a smaller cross-sectional area 72 than the cross sectional area 70 of the main line, thereby increasing the velocity of the gas-liquid flow 12 within the flow shaping line 17 . The increase in velocity of the gas-liquid flow 12 results in greater centrifugal force and increased concentration of the gas 22 on the inner wall 24 of the flow shaping line 17 . A higher velocity through the flow shaping line 17 also allows for greater turndown capability in the flow rate of the gas-liquid 12 in a system where the flow rate may be variable.
In other embodiments, as illustrated in FIG. 6 , the flow pattern could be elliptical 80 , or partially circular or partially elliptical, or some other curvilinear, non-circular shape that would still provide for increased concentration of the gas 22 on the inner wall 24 of the flow shaping line 17 through the use of centrifugal force.
As seen in FIG. 7 , other embodiments of the invention may employ multiple outlet ports 28 . For example, in one embodiment, an outlet port 28 may extend from the approximate bottom of a first loop, similar to the embodiment of FIG. 2 , but the pipe may continue to make a second loop similar to the embodiment of FIG. 4 , and have a similarly situated second outlet port 28 at the approximate bottom of the second loop. In addition, in another embodiment, one or more conventional separators may be used.
Other embodiments of the invention may eliminate the fluid guiding surface 30 or utilize other structures. For example, as illustrated in FIG. 8 , in one embodiment, an outlet port 28 may have a curved entrance 82 . In another embodiment illustrated in FIG. 9 , a fluid guiding surface 84 could be spaced away from the inner wall 24 of the flow shaping line. In addition, other embodiments of the invention may use a nozzle or other type of restriction in lieu of a venturi to accelerate the fluid flow across the outlet port 28 or across the liquid inlet port 42 , or may use no restriction at all.
As described above, one application for the invention is to protect against “kicks,” such as in subsea applications, by circulating out hydrocarbon gas at the seabed floor before the gas is able to rise up to a drilling rig. Referring to FIG. 10 , in an exemplary embodiment, illustrated is a conventional sub-sea blow out preventer 50 located on the seafloor 52 . A marine riser 54 extends from the blow out preventer 50 and within the riser is a drillpipe 56 . An embodiment of the separation apparatus 10 is positioned along drillpipe 56 , preferably adjacent the blow out preventer 50 . In normal drilling operations, drilling fluid 58 is pumped down the drillpipe 56 from the drilling rig (not shown) and returns to the drilling rig via annulus 60 formed between the drillpipe 56 and the riser 54 . If a “kick” is detected, for example, by a change in the level of the mud tanks or increase in mud circulation rate, inlet annulus valve 62 is activated, diverting drilling fluid 58 from annulus 60 into the flow shaping line 17 . Natural gas 64 entrained in drilling fluid 58 from the “kick” is then separated from the drilling fluid 58 by the separation apparatus 10 as described above. The natural gas 64 exits the gas-liquid separator 38 at the gas exit 39 and may flow up riser 66 to the drilling rig where it may be safely handled, for example, sent to a flare boom of the drilling rig (not shown), or compressed and re-distributed (also not shown).
Following separation of natural gas 64 from the drilling fluid 58 by separation apparatus 10 , the drilling fluid 58 is re-introduced into the annulus 60 at an exit annulus valve 68 . In comparison with the usual procedure of handling a kick, the use of an embodiment of this invention allows for full flow or circulation of the drilling fluid without having to choke down the flow or operate the blow out preventer valves.
In another embodiment, the inlet annulus valves 62 or exit annulus valves 68 can be eliminated, bypassed or operated so that the upward flowing drilling fluid 58 continually flows through the separation apparatus 10 . Compared to the usual procedure on a drilling rig when there is a kick of choking the flow of the drilling fluid and being able to only send a portion of the flow to the mud-gas separator located on the drilling rig, an embodiment of the present invention allows the full flow of the drilling fluid to be handled by the separation apparatus 10 and the separation safely takes place near the seafloor.
The foregoing invention allows the use of a separation apparatus that can efficiently separate gas from a gas-liquid flow and do so at high flow rates and with the use of smaller conventional separators than would otherwise be possible at the high flow rates.
It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present invention. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee.
Although illustrative embodiments of the invention have been shown and described, a wide range of modification, changes and substitution is contemplated in the foregoing disclosure. In some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | A two phase gas-liquid separation apparatus is provided that shapes the flow in a flow shaping line. Shaping the two-phase flow allows centrifugal force to send the heavier, denser liquid to the outside wall of the flow shaping line and allows the lighter, less dense vapor or gas to occupy the inner wall of the flow shaping line. With the gas positioned on the inner wall of the flow shaping line, an exit port on the inner wall will allow for the majority, if not all, of the gas, along with a low amount of liquid, to be sent to a conventional separator. A high ratio of vapor/liquid at a flow rate much lower than the total flow rate within the flow shaping line is sent to the conventional separator. This allows for efficient separation of the vapor from the liquid with the use of a smaller conventional separator. | 4 |
FIELD OF THE INVENTION
The invention relates to a method and apparatus for gas chromatography analysis of samples.
To use gas chromatography to investigate small quantities of components present in gases or liquids, such as foreign substances or pollutants or impurities, it is known firstly to enrich these in order then to feed them into a gas chromatograph via an appropriate feeding system. However, problems occur in this case when the collected samples contain moisture such as is the case, for example, when pollutants contained in the air are enriched, since the moisture contained in the air is then also enriched.
However, water severely disturbs a gas chromatography system, and likewise the analysis, in the case of which, for example, a substantial loss in sensitivity occurs in the mass spectrometer. The presence of water in separation columns alters the retention time, doing so, specifically, as a function of quantity and differently for different substances, thus creating the need to eliminate this as completely as possible in order to obtain reliable measurement results.
BACKGROUND OF THE INVENTION
It is known to eliminate the moisture which is present in samples to be chromatographically analyzed by osmosis. However, this has the disadvantage that polar components are also eliminated in the process, while non-polar components remain essentially uninfluenced. However, the elimination of polar components other than water falsifies the chromatogram.
Also known are packed capillary columns which exhibit a temperature-dependent adsorptivity with reference to water, so that given appropriate setting, low-boiling components are passed while higher-boiling components and water are retained.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a method for gas chromatography analysis of samples which permits reliable gas chromatograms to be obtained from samples containing water.
It is a further object of the invention to provide an apparatus for gas chromatography analysis of samples which permits reliable gas chromatograms to be obtained from samples containing water.
According to the invention a method for gas chromatography analysis of a sample after preceding thermodesorption, in which the components to be separated and water are contained, is provided,
wherein the thermodesorbed sample is transferred by means of carrier gas into a first polar separation column which retains higher-boiling components and water and passes low-boiling components,
said low boiling components being led, past a branching device which leads, on the one hand, to a second polar or non-polar separation column and, on the other hand, to a non-polar separation column, to the non-polar separation column in a fashion excluding access to the second polar or non-polar separation column,
after which the higher-boiling components and the water are lead to the second polar or non-polar separation column in a manner excluding access to the non-polar separation column,
the water being eliminated upstream of the second polar or non-polar separation column by means of cryofocussing.
According to the invention, further an apparatus for gas chromatography analysis of a sample is provided, comprising:
a thermodesorption device for holding a sampling tube;
a first polar separation column being connected downstream of the thermodesorption device;
a branching device being connected downstream of the first polar separation column;
a non-polar separation column;
a second separation column being of the group of a polar and a non-polar separation column;
wherein said branching device being switchable over between said non-polar separation column; and
a device for eliminating water which is connected upstream of the second separation column.
By virtue of the fact that according to the present invention use is made as a precolumn of a polar separation column with a stationary phase, which water does not initially have the effect of separating it preliminarily into two fractions, higher-boiling components and water can be retained at the beginning, while low-boiling components are passed. The low-boiling components are separated on the non-polar separation column via a pneumatically closeable bifurcation which leads, on the one hand, to a non-polar separation column for gases and, on the other hand, via a cryofocussing device, to a further polar or non-polar separation column, whereupon after pneumatically switching over the bifurcation the water with higher-boiling components is eliminated in the region of the cryofocussing device, whereupon the higher-boiling components are separated in the polar or non-polar separation column downstream of the cryofocussing device. In addition, in this case the water elimination with subsequent separation and analysis of a sample, and the separation on the further separation column with subsequent analysis of another sample, can be carried out simultaneously.
In this case, not only gaseous but also liquid samples which contain water can be taken automatically by means of the apparatus.
Further objects, embodiments and advantages of the invention will become apparent from the following description and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained below in more detail with reference to preferred embodiment illustrated schematically in the attached illustrations.
FIG. 1 shows a diagram of a gas chromatography apparatus according to the invention, partially in section.
FIG. 2 shows the diagrammatic design of an embodiment of a thermodesorption device or cryofocussing device or a device for eliminating water for the gas chromatography device of FIG. 1, in section.
FIG. 3 shows a diagram of a design of a branching point for the gas chromatography device of FIG. 1, in section.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The gas chromatography apparatus illustrated in FIG. 1 comprises a thermodesorption device 1 for a sample contained in a sampling tube 2 , a carrier gas connection 3 and a gas exhaust line 4 being provided. A transfer capillary 7 leading from the thermodesorption device 1 to a feed head 5 of a cryofocussing device 6 can be heated by a transfer furnace 8 in order to avoid material losses upon transfer from the sampling tube 2 to the cryofocussing device 6 . The cryofocussing device 6 comprises a gas exhaust line 9 . A transfer capillary 10 a , 10 b downstream of the cryofocussing device 6 leads, if appropriate, via a switchover valve 11 to a column collecting piece 12 of a polar separation column 13 serving as capillary precolumn, the column connecting piece 12 comprising a gas exhaust line 14 . The switchover valve 11 also comprises several feed or discharge lines 11 a - 11 d for flushing, calibration or automatic sampling. The transfer capillary 10 a , 10 b is arranged in a transfer furnace 15 which can, if appropriate, form a common furnace with the transfer furnace 8 .
A branching device 16 is arranged at the end downstream of the polar separation column 13 , which exhibits stable properties with regard to separation in the presence of water. Separation columns 17 , 18 are connected separately from one another to the branching device 16 , it being possible to exclude pneumatically the access to in each case one of the separation columns 17 , 18 via a gas line 19 , which can be charged with gas via a valve 20 or 21 and a controller 22 .
The separation column 17 is a non-polar separation column which, in particular, operates according to the principle of a micropacked column, and serves to separate low-boiling components. The separation column 17 is connected to an analyzer A 1 .
The separation column 18 is a polar or non-polar separation column with stable properties with regard to the separation of polar components. The separation column 18 is connected to an analyser A 2 . Connected upstream of the separation column 18 is a device 23 for eliminating water, which comprises a carrier gas connection 24 and a gas exhaust line 25 for the purpose of eliminating interfering water. In this case, a thermal conductivity detector 26 connected to the gas exhaust line 25 is used to monitor the completeness of the elimination.
The polar separation column 13 can be arranged in a furnace 27 which can, if appropriate, form a single furnace with the transfer furnace 8 .
The capillary separation columns 17 , 18 are preferably arranged in the furnaces 28 and 29 , respectively, but they can also be arranged in a common furnace, if appropriate together with the polar separation column 13 .
The device 23 , illustrated in FIG. 2, for eliminating water comprises a cooling device, which can be formed by a Peltier element, a cyrostat or a passage for liquefied gas such as liquid nitrogen. In the exemplary embodiment illustrated, a housing casing 30 is provided with coolant bores 31 which can be connected to a coolant source, the housing casing 30 accommodating a metal tube 33 which is surrounded by a heating winding 32 and for its part accommodates the sampling tube 2 . An annular gap 34 which is connected to the gas exhaust line 25 is located between the metal tube 33 and the sampling tube 2 . The carrier gas connection 24 opens into the sampling tube 2 in the region of a feed head 35 . The separation column 18 is plugged into the device 23 for eliminating water in such a way that it projects into the sampling tube 2 . Since the inside diameter of the sampling tube 2 is larger than the outside diameter of the separation column 18 , the interior of the sampling tube 2 is also connected to the annular gap 34 .
The thermodesorption device 1 and the cryofocussing device 6 can be designed in a fashion corresponding to the device 23 for eliminating water, and so reference is made to FIG. 2 in each case in connection with these devices. The design can be selected, for example, to accord with DE 44 19 596 C1, but it is also possible here to provide cooling by a Peltier element or a cryostat, while consideration may be given respectively in this connection to a heating cartridge for example in accordance with DE 198 17 017 A1. However, if appropriate, the annular gap 34 and the gas exhaust line 4 or 9 can be dispensed with, if appropriate, in the case of the thermodesorption device 1 and the cryofocussing device 6 when split-mode operation is not desired. The thermodesorption device 1 can be designed as in the case where sampling tubes 2 are to be used such as described, for example, in DE 195 20 715 C1. Each of DE 44 19 596 C1, DE 198 17 017 A1, and DE 195 20 715 C1 is incorporated herein by reference, as are any English-language equivalents thereof.
In the embodiment of the branching device 16 of FIG. 3, a central branching piece 36 is connected to two further branching pieces 37 , 38 via capillary adapters 39 which, for their part, are connected via the valve 20 or 21 and the controller 22 to the gas line 19 or to the separation column 17 or 18 , it being possible, if appropriate, to connect the central branching piece 36 to a monitor detector 40 , in particular a thermal conductivity detector.
A sample contained in the sampling tube 2 is thermodesorbed in the thermodesorption device 1 by controlled heating of the sampling tube 2 by means of the heating winding 32 . During thermodesorption, carrier gas is fed into the sampling tube 2 via the carrier gas connection 3 , and led into the cryofocussing device 6 via the heated transfer capillary 7 for the purpose of transporting desorbed substances, including water which is present. Uniform feeding of carrier gas is maintained constant in this case in each method step via a flow sensor with a controller. Since thermodesorption is performed without splitting, the gas exhaust line 4 remains closed and thereby pneumatically closes the access to the annular gap 34 .
Initially, the cryofocussing device 6 is closed off at the end, if appropriate by means of the switchover valve 11 , from the column connecting piece 12 , its gas exhaust line 9 is opened, for example via a valve (not illustrated), and its sampling tube 2 is cooled down to minus 150° C. by appropriate cooling, for example with liquid nitrogen, such that all the components of the sample which are to be investigated, including the water contained, are collected in the sampling tube 2 and thus enriched. Thereafter, the gas exhaust line 9 is closed, while the sampling tube 2 is heated up, while being monitored, to a temperature of, for example, 350° C., by means of the heating winding 32 , all the enriched components leaving the sampling tube 2 of the cryofocussing device 6 and now being led into the separation column 13 by means of carrier gas because of the open switchover valve 11 via the column connecting piece 12 .
The preliminary separation into two fractions of the separation column 13 is initially not influenced by water which is present, and higher-boiling components and water are retained there by interaction forces of different strength for a longer time than low-boiling, essentially non-polar components.
In the first phase of the separation by the polar separation column 13 in which the furnace 27 is at ambient temperature, the low-boiling non-polar components, i.e. those with one to approximately four or more carbon atoms, flow through the polar separation column 13 virtually without a separation effect, and subsequently through the branching device 16 . The valve 20 is opened in this case, and so the branching device 16 is pneumatically closed towards the polar or non-polar separation column 18 , and the low-boiling non-polar components are permitted to pass to the non-polar separation column 17 by means of a controlled carrier gas flow. These components are separated in the non-polar separation column 17 and analyzed in the analyzer A 1 .
In a second phase of the separation by the polar separation column 13 , the valve 20 is closed and the valve 21 is opened such that the branching device 16 is now pneumatically closed off from the non-polar separation column 17 . The valves 20 , 21 are switched over in principle as a function of time, the switch over being calibrated to a retention time of a specific compound, which is low boiling by comparison with water, in the non-polar separation column 17 , for example to the retention time of toluene, but it can also be performed earlier, if appropriate, when the monitor detector 40 which reacts to water outputs a signal on the basis of incoming water which has the effect of permitting access by higher-boiling components and water on the basis of the now reversed direction of the overall gas flow to the polar separation column 18 via the device 33 for eliminating water, the polar separation column 13 then being additionally heated via the furnace 27 in order to release all higher-boiling components and/or water.
The device 23 for eliminating water permits higher-boiling components to be separated from water in three phases.
In a first phase, the cryofocussing, the higher-boiling components and water are collected and enriched—as in the case of enrichment in the cryofocussing device 6 . In a second phase, the sampling tube 2 of the device 23 for eliminating water is heated by means of its heating winding 32 , the water being eliminated via the open gas exhaust line 25 . This heating is performed to a temperature above the freezing point of water and below the boiling point of water, preferably to a relatively low temperature of, for example, 10 to 20° C., this temperature being selected in such a way that as little loss of components as possible results in this case, but an adequate water vapor partial pressure is present. The monitoring of the water content in the sample is performed in this case by means of the thermal conductivity detector 26 , which reacts to the presence of water and is connected to the gas exhaust line 25 . Once the water has been completely eliminated, the gas exhaust line 25 is closed on the basis of a signal output by the thermal conductivity detector 26 , whereupon in the third phase the sampling tube 2 of the device 23 for eliminating water is heated further in a programmed fashion by means of the heating winding 32 , and the individual components are released again one after another and are then led into the polar or non-polar separation column 18 in which they are successively separated and analyzed in the analyzer A 2 .
Water is eliminated in the device 23 for eliminating water by virtue of the fact that its sampling tube 2 is heated by means of the heating winding 32 , and that, with the gas exhaust line 25 open, the carrier gas flowing past a fed sample containing water flows to the polar or non-polar separation column 18 at the end, averted from the feed head 35 , of the sampling tube 2 of the device 23 for eliminating water, back to the gas exhaust line 25 through the annular gap 34 , and is thereby eliminated. This form of elimination of individual components, also termed split-mode operation, can also take place in the cryofocussing device 6 by means of a gas exhaust line 9 , which is open here, and in the thermodesorption device 1 by means of a gas exhaust line 4 , which is open here. The gas exhaust lines 4 , 9 and 25 each have a valve which is opened, preferably pneumatically, by means of pressure control during split-mode operation.
It is expedient for the sample to be introduced quickly in the column connecting piece 12 on the basis of operation as a consequence of a continuously open gas exhaust line 14 by means of the flow velocity, thereby increased, in order in this way to achieve a defined peak end (avoidance of peak tailing) with a defined sharpness of separation. Thinning of the sample resulting therefrom is generally acceptable.
A sample can be introduced into the thermodesorption device 1 by means of an exchangeable sampling tube 2 . Instead of this, the sample can, however, also be collected in the sampling tube 2 of the thermodesorption device 1 by the sucked-in ambient atmosphere during split-mode operation with the gas exhaust line 9 open, the gas being eliminated via the annular gap 34 and the gas exhaust line 9 . If appropriate, the switchover valve 11 can, also be arranged upstream of the cryofocussing device 6 in the region of the transfer capillary 7 .
The switchover valve 11 is adjusted after a passage of the sample in such a way that firstly, with the aid of the now connected feed line 11 a and 11 b the sample inlet is flushed up to the outlet, and secondly, with the aid of the likewise connected transfer capillary 10 a , the feed line 11 a and 11 b , and also the connected feed line to the carrier gas connection 3 , the thermodesorption device 1 and the cryofocussing device 6 are flushed, while because of the closed exhaust line 14 the sample is led further to the column interface 12 via the polar separation column 13 . Consequently, on the basis of the above circuit it is possible to take a new sample in parallel with the sample to be analyzed or to carry out a calibration of the thermodesorption device 1 and of the cryofocussing device 6 .
In a preferred embodiment, the separation columns 13 , 17 and 18 are likewise arranged in individual furnaces 27 , 28 and 29 such that after passage of the respective sample the separation columns 13 , 17 , 18 are cooled down individually and prepared for the subsequent sample, the temperature intervals being selected to be smaller by the furnace 27 , 28 , 29 , which is to be assigned respectively to only one separation column 13 , 17 , 18 , and cooling taking place more quickly.
The pneumatic exclusion from the polar or non-polar separation column 18 via the device 23 for eliminating water, or from the non-polar separation column 17 is achieved on the basis of switching over the valves 20 , 21 and on the basis of the controller 22 , which sets a higher flow velocity of the gas from the gas line 19 than is prescribed by the carrier gas flow which flows through the polar separation column 13 . The capillary adapters 39 , which have a diameter of 50 μm to 100 μm, for example, are to be dimensioned in this case in terms of length and diameter and as a function of the gas pressure used in such a way that no diffusion takes place from the central branching piece 36 up to that one of the two branching pieces 37 , 38 which leads to the separation column 17 , 18 respectively not to be used.
While the invention has been shown and described with reference to a preferred embodiment, it should be apparent to one of ordinary skill in the art that many changes and modifications may be made without departing from the spirit and scope of the invention as defined in the claims. | The invention relates to gas chromatography analysis of a sample having components to be investigated and water contained therein, which after thermodesorption is separated and analyzed, the thermodesorbed sample being transferred by a carrier gas into a first polar separation column which retains higher-boiling components and water and passes low-boiling components, the latter being led, past a branching point which leads, on the one hand, to a second polar or non-polar separation column and, on the other hand, to the non-polar separation column, to the non-polar separation column in a fashion excluding access to the second polar or non-polar separation column, after which higher-boiling components and water are transferred to the second polar or non-polar separation column in a fashion excluding access to the non-polar separation column, water being eliminated upstream of the second polar or non-polar separation column by cryofocussing. | 6 |
BACKGROUND
The present invention generally relates to materials for use in shielding from heat and/or flame, and in particular, heat and/or flame shielding material that can be used in applications such as hood liners for automobiles, engine compartment liners, and the like.
Numerous industries require materials which not only deliver heat and flame resistant properties, but can also provide volume, opacity, moldability, and other properties in a cost effective single substrate. Often times these barrier properties are best accomplished by using specialty materials which generate a high level of performance, but also introduce significant cost to the substrate. Especially in a voluminous substrate (high z direction thickness) even the introduction of a small percent of these materials into the shield material can introduce a significant level of cost to the overall substrate. For this reason composites having specialty surface layers are often used to provide these barrier properties. An example of a composite having specialty surface layers would be a skin laminated to a voluminous lower cost material. While this method effectively reduces the cost of the high cost raw material, there are disadvantages to this method such as additional processing steps and the potential delamination of the skin layer.
The present invention provides an alternative to the prior art by using a unitary heat shield material with different zones to provide the various desired properties of the material
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
FIG. 1 shows an enlarged cross-section of one embodiment of the present invention;
FIG. 2 shows an enlarged cross-sectional view of another embodiment of the present invention; and,
FIG. 3 shows a diagram of a machine for performing a process for forming the planar heat and flame resistant shield material of the present invention.
DETAILED DESCRIPTION
Referring now to the figures, and in particular to FIG. 1 , there is shown an enlarged cross-sectional view of an embodiment of the present invention, illustrated as a planar heat and flame shield material 100 . The shield material 100 may be used in its existing sheet form as a protective blanket or shield in operations such as welding, high temperature manufacturing, or the like. The shield material 100 may also be formed into parts such as automotive hood liners, engine compartment covers, and the like. As illustrated, the planar shield material 100 generally contains heat and flame resistant fibers 101 and bulking fibers 102 . The heat and flame resistant fibers 101 and the bulking fibers 102 are staple fibers that are combined to form the shield material 100 . As used herein, heat and flame resistant fibers shall mean fibers having an Limiting Oxygen Index (LOI) value of 20.95 or greater, as determined by ISO 4589-1. Examples of heat and flame resistant fibers include the following: fibers including oxidized polyacrylonitrile, aramid, or polyimid, flame resistant treated fibers, carbon fibers, or the like. Bulking fibers are fibers that provide volume to the heat shield material. Examples of bulking fibers would include fibers with high denier per filament (one denier per filament or larger), high crimp fibers, hollow-fill fibers, and the like. In one embodiment, the heat and flame resistant fibers 101 and the bulking fibers 102 are air-laid with a binder fiber 105 , and the combination of fibers is heated to activate the binder fiber 105 for bonding together the fibers of the shield material 100 . An additional benefit of using the binder fiber 105 in the shield material 100 is that the shield material 100 can be subsequently molded to part shapes for use in automotive hood liners, engine compartment covers, etc.
Still referring to FIG. 1 , the heat and flame resistant fibers 101 are concentrated in a heat and flame resistant zone 110 of the planar shield material 100 , and the bulking fibers 102 are concentrated in a voluminous bulking zone 120 of the planar shield material 100 . The heat and flame resistant zone 110 provides the shield material 100 with the primary heat and flame resistant attributes. The voluminous bulking zone 120 provides the shield material 100 with the desired z-direction thickness.
Referring still to FIG. 1 , the heat and flame resistant zone 110 has an outer boundary 111 located at the outer surface of the shield material 100 , and an inner boundary 112 located adjacent to the voluminous bulking zone 120 . The voluminous bulking zone 120 has an outer boundary 121 located at the outer surface of the shield material 100 and an inner boundary 122 located adjacent to the heat and flame resistant zone 110 . The shield material 100 is a unitary material, and the boundaries of the two zones do not represent the delineation of layers, but areas within the unitary material. Because the shield material 100 is a unitary material, and the heat and flame resistant zone 110 and the voluminous bulking zone 120 are not discrete separate layers joined together, various individual fibers will occur in both the heat and flame resistant zone 110 and the voluminous bulking zone 120 . Although FIG. 1 illustrates the heat and flame resistant zone 110 being a smaller thickness than the voluminous bulking zone 120 , the relative thickness of the two zones can have a substantially different than as shown.
Referring still to FIG. 1 , the heat and flame resistant zone 110 contains both the heat and flame resistant fibers 101 and the bulking fibers 102 . However, the heat and flame resistant zone 110 primarily contains the heat and flame resistant fibers 101 . Additionally, the distribution of the fibers in the heat and flame resistant zone 110 is such that the concentration of the heat and flame resistant fibers 101 is greater at the outer boundary 111 of the heat and flame resistant zone 110 than the inner boundary 112 of that zone. Also, as illustrated, it is preferred that the concentration of the heat and flame resistant fibers 101 decreases in a gradient along the z-axis from the outer boundary 111 of the heat and flame resistant zone 110 to the inner boundary 112 of that zone.
Still referring to FIG. 1 , the voluminous bulking zone 120 contains both the heat and flame resistant fibers 101 and the bulking fibers 102 . However, the voluminous bulking zone 120 primarily contains the bulking fibers 102 . Additionally, the distribution of the fibers in the voluminous bulking zone 120 is such that the concentration of the bulking fibers 102 is greater at the outer boundary 121 of the voluminous bulking zone 120 than the inner boundary 122 of that zone. Also, as illustrated, it is preferred that the concentration of the bulking fibers 102 decreases in a gradient along the z-axis from the outer boundary 121 of the voluminous bulking zone 120 to the inner boundary 122 of that zone.
Referring now to FIG. 2 , there is shown an enlarged cross-sectional view of another embodiment of the present invention, illustrated as a heat and flame shield material 200 . As illustrated, the shield material 200 generally contains heat and flame resistant fibers 201 and bulking fibers 202 . The heat and flame resistant fibers 201 and the bulking fibers 202 are staple fibers that are combined to form the shield material 200 . In one embodiment, the heat and flame resistant fibers 201 and the bulking fibers 202 are air-laid with a binder fiber 205 , and the combination of fibers is heated to activate the binder fiber 205 for bonding together the fibers of the shield material 200 . An additional benefit of using the binder fiber 205 in the shield material 200 is that the shield material 200 can be subsequently molded to part shapes for use in automotive hood liners, engine compartment covers, etc.
Still referring to FIG. 2 , the heat and flame resistant fibers 201 are concentrated in a heat and flame resistant zone 210 of the shield material 200 , and the bulking fibers 202 are concentrated in a voluminous bulking zone 220 of the shield material 200 . The heat and flame resistant zone 210 provides the shield material 200 with the primary heat and flame resistant attributes of the shield material 200 . The voluminous bulking zone 220 provides the shield material 200 with the desired z-direction thickness.
Referring still to FIG. 2 , the heat and flame resistant zone 210 has an outer boundary 211 located at the outer surface of the shield material 200 , and an inner boundary 212 located adjacent to the voluminous bulking zone 220 . The voluminous bulking zone 220 has an outer boundary 221 located at the outer surface of the shield material 200 and an inner boundary 222 located adjacent to the heat and flame resistant zone 210 . The shield material 200 is a unitary material, and the boundaries of the two zones do not represent the delineation of layers, but areas within the unitary material. Because the shield material 200 is a unitary material, and the heat and flame resistant zone 210 and the voluminous bulking zone 220 are not discrete separate layers joined together, various individual fibers will occur in both the heat and flame resistant zone 210 and the voluminous bulking zone 220 . Although FIG. 2 illustrates the heat and flame resistant zone 210 being a smaller thickness than the voluminous bulking zone 220 , the relative thickness of the two zones can have a substantially different than as shown.
Still referring to FIG. 2 , the heat and flame resistant zone 210 contains both the heat and flame resistant fibers 201 and the bulking fibers 202 . However, the heat and flame resistant zone 210 primarily contains the heat and flame resistant fibers 201 . Additionally, the distribution of the fibers in the heat and flame resistant zone 210 is such that the concentration of the heat and flame resistant fibers 201 is greater at the outer boundary 211 of the heat and flame resistant zone 210 than the inner boundary 212 of that zone. Also, as illustrated, it is preferred that the concentration of the heat and flame resistant fibers 201 decreases in a gradient along the z-axis from the outer boundary 211 of the heat and flame resistant zone 210 to the inner boundary 212 of that zone.
Referring still to FIG. 2 , the bulking fibers 202 of the shield material 200 comprise first bulking fibers 203 and second bulking fibers 204 . In one embodiment, the first bulking fibers have a higher denier per filament, and/or mass per fiber, than the heat and flame resistant fibers 201 , and the second bulking fibers 204 have a higher denier per filament, and/or mass per fiber, than the first bulking fiber 203 and the heat and flame resistant fibers 201 . Also, the voluminous bulking zone 220 is divided into a first bulking zone 230 and a second bulking zone 240 . The first bulking zone 230 has an outer boundary 231 located adjacent to the heat and flame resistant zone 210 and inner boundary 232 located adjacent to the second bulking zone 240 . The second bulking zone 240 has an outer boundary 241 located adjacent to the outer surface of the shield material 200 and an inner boundary 242 located adjacent to the first bulking zone 230 . As previously stated, the shield material 200 is a unitary material, and as such, the boundaries of the two bulking zones do not represent the delineation of layers, but areas with in the unitary material. Because the shield material 200 is a unitary material, and the first bulking zone 230 and the second bulking zone 240 are not discrete separate layers joined together, various individual fibers will occur in both the first bulking zone and the second bulking zone 240 . Although FIG. 2 illustrates the heat and flame resistant zone 210 being a smaller thickness than the voluminous bulking zone 220 , the relative thickness of the two zones can have a substantially different than as shown.
Still referring to FIG. 2 , the first bulking zone 230 contains both the first bulking fibers 203 and the second bulking fibers 204 . However, the first bulking zone 230 will contain more of the first bulking fibers 203 than the second bulking fibers 204 . The distribution of the fibers in the first bulking zone 230 is such that the concentration of the first bulking fibers 203 increases in a gradient along the z direction from the outer boundary 231 of the first bulking zone 230 to a first bulking fiber concentration plane 235 located between the inner boundary 232 and the outer boundary of the first bulking zone. Also, as illustrated, it is preferred that the concentration of the first bulking fibers 203 decreases in a gradient along the z-axis from the first bulking fiber concentration plane 235 to the inner boundary 232 of that zone.
Referring still to FIG. 2 , the second bulking zone 240 contains both the first bulking fibers 203 and the second bulking fibers 204 . However, the second bulking zone 240 will contain more of the second bulking fibers 204 than the first bulking fibers 203 . The distribution of the fibers in the second bulking zone 240 is such that the concentration of the second bulking fibers 204 is greater at the outer boundary 241 of the second bulking zone 240 than the inner boundary 242 of that zone. Also, as illustrated, it is preferred that the concentration of the second bulking fibers 204 decreases in a gradient along the z-axis from the outer boundary 241 of the second bulking zone 240 to the inner boundary 242 of that zone.
Still referring to FIG. 2 , the first bulking zone 230 will also contain heat and flame resistant fibers 201 . However, the first bulking zone 230 will contain more of the first bulking fibers 203 than the heat and flame resistant fibers 201 . The heat and flame resistant zone 210 can have some amount of the second bulking fiber 204 ; however, the amount of second bulking fiber 204 in the heat and flame resistant zone 210 is significantly lower than the first bulking fibers 203 . The second bulking zone 240 can also have some amount of the heat and flame resistant fibers 201 ; however, the amount of the heat and flame resistant fibers 201 in the second bulking zone is significantly lower than the first bulking fibers 203 . An advantage of using the two distinct bulking fibers 203 / 204 ( FIG. 2 ) over using a single bulking fiber 102 ( FIG. 1 ), is that for the same respective weights of heat and flame resistant fibers 101 / 201 and voluminous bulking fibers 102 / 202 , a shield material 200 having two types of bulking fibers 203 and 204 will have fewer heat and flame resistant fibers 201 located in the voluminous bulking zone 120 / 220 than a shield material 100 having only one type of bulking fiber 102 .
Referring now to FIG. 3 , there is shown a diagram of a particular piece of equipment 300 for the process to form the planar unitary heat and flame shield from FIGS. 1 and 2 . A commercially available piece of equipment that has been found satisfactory in this process to form the claimed invention is the “K-12 HIGH-LOFT RANDOM CARD” by Fehrer A G, in Linz, Austria. The heat and flame resistant fibers 101 / 201 and the voluminous bulking fibers 102 / 202 are opened and blended in the appropriate proportions and enter an air chamber 310 . In an embodiment using the binder fibers 105 / 205 , the binder fibers 105 / 205 are also opened and blended with the heat and flame resistant fibers 101 / 201 and the bulking fibers 102 / 202 prior to introduction into the air chamber 310 . In an embodiment where the voluminous bulking fibers 202 contain multiple types of bulking fibers 203 / 204 , those multiple types of bulking fibers 203 / 204 are also opened and blended in the appropriate portions with the other fibers before introduction into the air chamber 310 . The air chamber 310 suspends the blended fibers in air, and delivers the suspended and blended fibers to a roller 320 . The roller 320 rotates and slings the blended fibers towards a collection belt 330 . The spinning rotation of the roller 320 slings the heavier fibers a further distance along the collection belt 330 than it slings the lighter fibers. As a result, the mat of fibers collected on the collection belt 330 will have a greater concentration of the lighter fibers adjacent to the collection belt 330 , and a greater concentration of the heavier fibers further away from the collection belt 330 .
In the embodiment of the shield 100 illustrated in FIG. 1 , the heat and flame resistant fibers 101 are lighter than the voluminous bulking fibers 102 . Therefore, in the process illustrated in FIG. 3 , the heat and flame resistant fibers 101 collect in greater concentration near the collection belt 330 , and the voluminous bulking fibers 102 collect in greater concentration away from the collection belt 330 . It is this distribution by the equipment 300 that creates the heat and flame resistant zone 110 and the voluminous bulking zone 120 of the planar unitary shield material 100 .
In the embodiment of the shield 200 illustrated in FIG. 2 , the heat and flame resistant fibers 201 are lighter than the voluminous bulking fibers 202 . Therefore, in the process illustrated in FIG. 3 , the heat and flame resistant fibers 201 collect in greater concentration near the collection belt 330 , and the voluminous bulking fibers 202 collect in greater concentration away from the collection belt 330 . It is this distribution by the equipment 300 that creates the heat and flame resistant zone 210 and the voluminous bulking zone 220 of the planar unitary shield material 200 . Additionally, the first bulking fibers 203 of the voluminous bulking fibers 220 are lighter than the second bulking fibers 204 . Therefore, in the process illustrated in FIG. 3 , the first bulking fibers 203 are collected in greater concentration nearer the collection belt 330 than the second bulking fibers 204 . It is this distribution that creates the first bulking zone 230 and the second bulking zone 240 of the voluminous bulking zone 220 of the planar unitary shield material 200 .
In one example of the present invention, planar unitary heat and flame resistant shield material was formed from a blend of four fibers including:
1) 4% by weight of a heat and flame resistant fiber being 2 dpf partially oxidized polyacrylonitrile 2) 25% by weight of a first bulking fiber being 6 dpf polyester 3) 41% by weight of a second bulking fiber being 15 dpf polyester, and 4) 30% by weight of a low melt binder fiber being 4 dpf core sheath polyester with a lower melting temperature sheath.
The fibers were opened, blended and formed into a shield material using a K-12 HIGH-LOFT RANDOM CARD” by Fehrer AG. The shield had a weight per square yard of about 16–32 ounces and a thickness in the range of about 12–37 mm. In the resulting shield material, the heat and flame resistant fibers in the heat and flame resistant zone comprised at least 70% of the total fibers in that zone, and the heat and flame resistant fibers in the voluminous bulking zone were less than about 2% of the total fibers in that zone.
Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. For example, an additional layer of material such as a nonwoven can be added to the outside surface or the inside surface of the present invention for additional purposes. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. | A heat and fire resistant planar unitary shield formed of heat and flame resistant fibers and voluminous bulking fibers. The shield material has a heat and flame resistant zone with a majority of the heat and flame resistant fibers, and a voluminous bulking zone with a majority of the voluminous bulking fibers. The fibers are distributed through the shield material in an manner that the heat and flame resistant fibers collect closest to the outer surface of the shield with the heat and flame resistant zone, and the voluminous bulking fibers collect closest to the outer surface of the shield material with the voluminous bulking zone. | 3 |
CROSS REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/487,159, filed Jul. 14, 2003, the disclosure of which is hereby incorporated by reference.
FIELD OF INVENTION
[0002] The present invention relates to fabric assemblies for interior decoration, and more particularly, to bed covers, window treatments, and similar applications with removable parts that facilitate changes in room decor.
BACKGROUND
[0003] Typically, consumers decorate and re-decorate rooms of their houses, condominiums, or apartments multiple times. It can be very time-consuming and expensive to replace window treatments and bedding every time a consumer feels the need to re-decorate. It is also quite cumbersome to physically change bedding and re-hang window treatments.
[0004] Thus, there is a need for bed covers and window treatments that can be quickly and inexpensively replaced, adjusted, and interchanged with different styles of decoration for ease in decorating and re-decorating rooms to accommodate changes in room decor.
SUMMARY
[0005] The present invention provides a fabric assembly for interior decoration. The fabric assembly contains a base fabric having a receiving section adapted to receive a removable fabric section; one or more removable fabric sections adapted to be interchangeably attached to the receiving section; and fastening means for attaching the removable fabric section to the receiving section of the base fabric. The removable fabric section is affixed to the base fabric to create a decorative scheme, and the decorative scheme can be easily changed by replacing one removable fabric section with another removable fabric section.
[0006] The decorative fabric assembly is used as bedcover, window treatment, or for a similar application. The incorporation of the fastening means in the fabric assembly allows easy and quick removal or replacement of part of the fabric assembly, therefore facilitates change of room decor. Moreover, the interchangeability between components of different fabric assemblies provides consumers with more decorative options without increasing the cost of decoration.
[0007] These and other advantages, aspects, and features will be understood by one of ordinary skill in the art upon reading and understanding the specification.
BRIEF DESCRIPTION OF DRAWINGS
[0008] The invention may be described with greater clarity and particularity by reference to the accompanying drawings:
[0009] FIGS. 1A-1C depict an embodiment of the present invention, in which the fabric decorative assembly is used as a bedcover.
[0010] FIGS. 2A-2C depict another embodiment of the present invention, in which the fabric decorative assembly is used as a bedcover.
[0011] FIGS. 3A-3C depict another embodiment of the present invention, in which the fabric decorative assembly is used as a bedcover.
[0012] FIGS. 4A-4C depict another embodiment of the present invention, in which the fabric decorative assembly is used as a bedcover.
[0013] FIG. 5 depicts yet another embodiment of the present invention, in which the fabric decorative assembly is used as a window treatment.
DETAILED DESCRIPTION
[0014] The present invention is directed to fabric decorative assemblies having removable and interchangeable parts to provide versatility and facilitate re-decoration of beds, windows, and similar applications. A base fabric assembly includes one or more sections in which a removable or interchangeable section may be fixedly attached using various fastening means. The removable sections can be interchanged to produce different decorative effects. The fabric decorative assemblies are useful for bedcover and window treatment applications, for example. As used herein, the term “bedcover” refers to any fabric assembly used to cover the surface of a bed, including but are not limited to, comforters, sheets, bedspreads, quilts, throws, coverlets, and blankets. As used herein, the term “window treatment” refers to any fabric assembly used to cover a window or part of a window, including but are not limited to, curtains, valances, and draperies. Other applications include slip covers for sofas, chairs, and day beds, decorative wall panels, area rugs, shower curtains, doorway curtains, cabinet curtains, and similar applications.
[0015] FIGS. 1A-1C show an embodiment of the fabric decorative assembly that is used as a bedcover 100 . In this embodiment, the bedcover 100 contains a center panel 102 and a side panel 104 ( FIG. 1A ). As shown in FIG. 1B and 1C , the center panel 102 is removably attached to the side panel 104 using fasteners 106 . Alternatively, the center panel 102 may be fixed and the side panels 104 may be removable.
[0016] Based on the needs of a consumer, the center panel 102 and the side panel 104 can be made of the same type of fabric or different types of fabric. The center panel 102 and the side panel 104 can have the same or different color, pattern, or style. The fasteners 106 can be any type of fastening device as is known in the art, such as buttons, snaps, ribbons, zippers, Velcro, and hooks with string. Any number of fasteners 106 can be used, as long as the center panel 102 is securely fastened to the side panels 104 . Preferably, the fasteners 106 are located on a surface of the center panel 102 that is facing the side panel 104 and the fasteners 106 are not visible after the center panel 102 is secured to the side panel 104 . The center panel and the side panel 104 can be made of one or more layers of fabric or synthetic fabric, or a combination thereof.
[0017] The bedcover 100 allows a consumer to quickly and conveniently redecorate a bed by replacing the center panel 102 or the side panel 104 with a substitute panel of a different color, reflection, pattern, or style. The interchangeability also allows the consumer to create new decorative styles by making new center/side panel combinations from existing bedcovers 100 , therefore saving the expense of purchasing another bedcover 100 . The center panel 102 and side panels 104 , as well as the assembled bedcover 100 , can be of varying sizes, depending on the size of the bed and the consumer's needs. The area covered by the center panel 102 , designated area 108 , can be a continuous part of the side panel 104 . Alternatively, area 108 can be an open space on the side panel 104 and the center panel 102 is attached to the side panel 104 through fasteners 106 located along borders 110 of the area 108 .
[0018] FIGS. 2A-2C depict another embodiment of the fabric decorative assembly, generally designated as bedcover 200 . In this embodiment, there are one center panel 102 and multiple side panels 104 . The side panels 104 are attached to each other through fasteners 106 at the edges of each side panel 104 . The side panels 104 can also be attached to the center panel 102 in various combinations desired by a consumer. For example, a consumer may decide to attach one, two, three, or four side panels 104 to the center panel 102 to fit beds of different sizes or decorate the same bed in different styles. This embodiment thus provides more flexibility and interchangeability in the use of the bedcover 200 which, when combined with other bedcovers 200 , would allow an even larger number of possible combinations and vastly expanded decorative choices.
[0019] FIGS. 3A-3C depict yet another embodiment of the fabric decorative assembly as bedcover 300 . In this embodiment, the center panel 102 has a length that is the same as the length of the side panel 104 and a width that is smaller than the width of the side panel 104 . Preferably, the center panel 102 is removably attached to the side panel 104 through fasteners 106 that are not visible after attachment. In this embodiment, the side panel 104 is a single piece of fabric and the center panel 102 covers the center portion 108 of the side panel 104 . Alternatively, there can be two side panels 104 and 104 ′, each attached to one side of the center panel 102 through fasteners 106 , as shown in FIGS. 4A-4C .
[0020] FIG. 5 shows another embodiment of the fabric decorative assembly as a window treatment 500 . The window treatment 500 contains a top panel 502 and a lower panel 504 . The top panel 502 is preferably attached to a rail or board or any kind of support above a window. The lower panel 504 is removably attached to the top panel 502 using fasteners 506 . Based on the needs of a consumer, the top panel 502 and the lower panel 504 can be made of the same type of fabric or different types of fabric. The top panel 502 and the lower panel 504 can also have the same or different color, pattern, or style. The fasteners 506 can be any type of fastening device known in the art, such as buttons, snaps, ribbons, zippers, Velcro, and hooks with string. Any number of fasteners 506 can be used, as long as the lower panel 504 is securely fastened to the top panel 502 . The fasteners 506 allow the lower panel 504 to be detached from and reattached to the top panel 502 , so that lower panels of various color, size, and style can be interchanged easily and quickly, depending on the consumers' needs.
[0021] In other embodiments, the fabric decorative assembly can be used to decorate beds in the form of comforters, sheets, bedspreads, quilts, throws, coverlets, blankets, and windows in the form of curtains, valances, draperies, and the like. The fabric decorative assembly can also be used as slip covers for sofas, chairs, and day beds, decorative wall panels, area rugs, shower curtains, doorway curtains, cabinet curtains, and other similar applications. The removable and interchangeable feature of the fabric decorative assembly allows easy and quick rearrangement of panels of different sizes, colors, and styles and, therefore, facilitates changes in room decor.
[0022] The fabric decorative assembly may be packaged as a kit that includes the base fabric and one or more interchangeable, removable fabric sections. Additional interchangeable, removable fabric sections may be acquired to supplement the fabric decorative assembly kit. Thus, a consumer may purchase the fabric decorative assembly kit. When the consumer decides to change decor, but is no longer satisfied with the decorative choices in the kit, the consumer may purchase additional interchangeable, removable fabric sections that suit the consumer's current decorating ideas.
[0023] Although the preferred embodiment has been described in detail, it should be understood that various changes, substitutions, and alterations can be made therein without departing from the scope of the invention. It will be appreciated that various changes in the details, materials and arrangements of parts, which have been herein described and illustrated in order to explain the nature of the invention, may be made by those skilled in the area within the principle and scope of the invention. | The present invention provides a fabric assembly for interior decoration. The fabric assembly contains a base fabric having a receiving section adapted to receive a removable fabric section; one or more removable fabric sections adapted to be interchangeably attached to the receiving section; and fastening means for attaching the removable section to the receiving section of the base fabric. The removable fabric section is affixed to the base fabric to create a decorative scheme, and the decorative scheme can be easily changed by replacing the existing removable fabric section with another removable fabric section. The interchangeability between different removable fabric sections provides consumers with more decorative options without increasing the cost of decoration. | 0 |
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.