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FIELD OF THE INVENTION
This invention relates to improvements in preventing heat- and moisture-shrink problems in specific polypropylene fibers. Such fibers require the presence of certain compounds that quickly and effectively provide rigidity to the target polypropylene fiber after heat-setting. Generally, these compounds include any structure that nucleates polymer crystals within the target polypropylene after exposure to sufficient heat to melt the initial pelletized polymer and upon allowing such a melt to cool. The compounds must nucleate polymer crystals at a higher temperature than the target polypropylene without the nucleating agent during cooling. In such a manner, the “rigidifying” nucleator compounds provide nucleation sites for polypropylene crystal growth. After drawing the nucleated composition into fiber form, the fiber is then exposed to sufficient heat to grow the crystalline network, thus holding the fiber in a desired position. The preferred “rigidifying” compounds include dibenzylidene sorbitol based compounds, as well as less preferred compounds, such as sodium benzoate, certain sodium and lithium phosphate salts (such as sodium 2,2′-methylene-bis-(4,6-di-tert-butylphenyl)phosphate, otherwise known as NA-11). Specific methods of manufacture of such fibers, as well as fabric articles made therefrom, are also encompassed within this invention.
DISCUSSION OF THE PRIOR ART
There has been a continued desire to utilize polypropylene fibers in various different products, ranging from apparel to carpet backings (as well as carpet pile fabrics) to reinforcement fabrics, and so on. Polypropylene fibers exhibit excellent strength characteristics, highly desirable hand and feel, and do not easily degrade or erode when exposed to certain “destructive” chemicals. However, even with such impressive and beneficial properties and an abundance of polypropylene, which is relatively inexpensive to manufacture and readily available as a petroleum refinery byproduct, such fibers are not widely utilized in products that are exposed to relatively high temperatures during use, cleaning, and the like. This is due primarily to the high and generally non-uniform heat- and moisture-shrink characteristics exhibited by typical polypropylene fibers. Such fibers are not heat stable and when exposed to standard temperatures (such as 150° C. and 130° C. temperatures), the shrinkage range from about 5% (in boiling water) to about 7-8% (for hot air exposure) to 12-13% (for higher temperature hot air). These extremely high and varied shrink rates thus render the utilization and processability of highly desirable polypropylene fibers very low, particularly for end-uses that require heat stability (such as apparel, carpet pile, carpet backings, molded pieces, and the like). To date, there has been no simple solution to such a problem. Some ideas have included narrowing and controlling the molecular weight distribution of the polypropylene components themselves in each fiber or mechanically working the target fibers prior to and during heat-setting. Unfortunately, molecular weight control is extremely difficult to accomplish initially, and has only provided the above-listed shrink rates (which are still too high for widespread utilization within the fabric industry). Furthermore, the utilization of very high heat-setting temperatures during mechanical treatment has, in most instances, resulted in the loss of good hand and feel to the subject fibers. Another solution to this problem is preshrinking the fibers, which involves winding the fiber on a crushable paper package, allowing the fiber to sit in the oven and shrink for long times, (crushing the paper package), and then rewinding on a package acceptable for further processing. This process, while yielding an acceptable yarn, is expensive, making the resulting fiber uncompetitive as compared to polyester and nylon fibers. As a result, there has not been any teaching or disclosure within the pertinent prior art providing any heat- and/or moisture-shrink improvements in polypropylene fiber technology.
DESCRIPTION OF THE INVENTION
It is thus an object of the invention to provide improved shrink rates for standard polypropylene fibers. A further object of the invention is to provide a class of additives that, in a range of concentrations, will give low shrinkage. A further object of the invention is to provide a specific method for the production of nucleator-containing polypropylene fibers permitting the ultimate production of such low-shrink fabrics therewith. Accordingly, this invention encompasses a polypropylene fiber possessing at most 5,000 denier per filament and exhibiting a heat-shrinkage in at least 150° C. hot air of at most 11%, wherein said fiber further comprises at least one nucleating agent. Also, this invention encompasses a polypropylene fiber possessing at most 5,000 denier per filament and exhibiting a heat-shrinkage in at least 150° C. hot air of at most 11%, wherein said fiber further comprises at least one nucleating agent, and wherein said fiber further exhibits a long period of at least 20 nm as measured by small-angle x-ray scattering. Furthermore, this invention encompasses a polypropylene fiber possessing at most 5,000 denier per filament and comprising at least one nucleating agent, and wherein said fiber further exhibits a long period of at least 20 nm as measured by small-angle x-ray diffraction spectroscopy. Additionally, this invention encompasses a polypropylene fiber possessing at most 5,000 denier per filament and exhibiting a peak crystallization temperature of at least 115° C. as measured by differential scanning calorimetry in accordance with a modified ASTM Test Method D3417-99 at a cooling rate of 20° C./min, and wherein said fiber further exhibits a long period of at least 20 nm as measured by small-angle x-ray scattering. Certain yarns and fabric articles comprising such inventive fibers are also encompassed within this invention.
Furthermore, this invention also concerns a method of producing such fibers comprising the sequential steps of a) providing a polypropylene composition in pellet or liquid form comprising at least 100 ppm by weight of a nucleator compound; b) melting and mixing said polypropylene composition of step “a” to form a substantially homogeneous molten plastic formulation; c) extruding said plastic formulation to form a fiber structure; d) mechanically drawing said extruded fiber (optionally while exposing said fiber to a temperature of at most 105° C.); and e) exposing said drawn fiber of step “d” to a subsequent heat-setting temperature of at least 110° C. Preferably, step “b” will be performed at a temperature sufficient to effectuate the melting of all polymer constituent (e.g., polypropylene), and possibly the remaining compounds, including the nucleating agent, as well (melting of the nucleating agent is not a requirement since some nucleating agents do not melt upon exposure to such high temepratures). Thus, temperatures within the range of from about 175 to about 300° C., as an example (preferably from about 200 to about 275°, and most preferably from about 220 to about 250° C., are proper for this purpose. The extrusion step (“c”) should be performed while exposing the polypropylene formulation to a temperature of from about 185 to about 300° C., preferably from about 210 to about 275° C., and most preferably from about 230 to about 250° C., basically sufficient to perform the extrusion of a liquefied polymer without permitting breaking of any of the fibers themselves during such an extrusion procedure. The drawing step may be performed at a temperature which is cooler than normal for a standard polypropylene (or other polymer) fiber drawing process. Thus, if a cold-drawing step is followed, such a temperature should be below about 105° C., more preferably below about 100° C., and most preferably below about 90° C. Of course, higher temperatures may be used if no such cold drawing step is followed. The final heat-setting temperature is necessary to “lock” the polypropylene crystalline structure in place after extruding and drawing. Such a heat-setting step generally lasts for a portion of a second, up to potentially a couple of minutes (i.e., from about {fraction (1/10)} th of a second, preferably about ½ of a second, up to about 3 minutes, preferably greater than ½ of a second). The heat-setting temperature must be greater than the drawing temperature and must be at least 110° C., more preferably at least about 115°, and most preferably at least about 125° C. The term “mechanically drawing” is intended to encompass any number of procedures which basically involve placing an extensional force on fibers in order to elongate the polymer therein. Such a procedure may be accomplished with any number of apparatus, including, without limitation, godet rolls, nip rolls, steam cans, hot or cold gaseous jets (air or steam), and other like mechanical means.
In another embodiment of the method of making such inventive fibers, step “c” noted above may be further separated into two distinct steps. A first during which the polymer is extruded as a sheet or tube, and a second during which the sheet or tube is slit into narrow fibers of less than 5000 deniers per filament (dpf).
All shrinkage values discussed as they pertain to the inventive fibers and methods of making thereof correspond to exposure times for each test (hot air and boiling water) of about 5 minutes. The heat-shrinkage at about 150° C. in hot air is, as noted above, at most 11% for the inventive fiber; preferably, this heat-shrinkage is at most 9%; more preferably at most 8%; and most preferably at most 7%. Also, the amount of nucleating agent present within the inventive fiber is at least 10 ppm; preferably this amount is at least 100 ppm; and most preferably is at least 1250 ppm. Any amount of such a nucleating agent should suffice to provide the desired shrinkage rates after heat-setting of the fiber itself; however, excessive amounts (e.g., above about 10,000 ppm and even as low as about 6,000 ppm) should be avoided, primarily due to costs, but also due to potential processing problems with greater amounts of additives present within the target fibers.
The term “polypropylene” is intended to encompass any polymeric composition comprising propylene monomers, either alone or in mixture or copolymer with other randomly selected and oriented polyolefins, dienes, or other monomers (such as ethylene, butylene, and the like). Such a term also encompasses any different configuration and arrangement of the constituent monomers (such as syndiotactic, isotactic, and the like). Thus, the term as applied to fibers is intended to encompass actual long strands, tapes, threads, and the like, of drawn polymer. The polypropylene may be of any standard melt flow (by testing); however, standard fiber grade polypropylene resins possess ranges of Melt Flow Indices between about 2 and 50. Contrary to standard plaques, containers, sheets, and the like (such as taught within U.S. Pat. No. 4,016,118 to Hamada et al., for example), fibers clearly differ in structure since they must exhibit a length that far exceeds its cross-sectional area (such, for example, its diameter for round fibers). Fibers are extruded and drawn; articles are blow-molded or injection molded, to name two alternative production methods. Also, the crystalline morphology of polypropylene within fibers is different than that of standard articles, plaques, sheets, and the like. For instance, the dpf of such polypropylene fibers is at most about 5000; whereas the dpf of these other articles is much greater. Polypropylene articles generally exhibit spherulitic crystals while fibers exhibit elongated, extended crystal structures. Thus, there is a great difference in structure between fibers and polypropylene articles such that any predictions made for spherulitic particles (crystals) of nucleated polypropylene do not provide any basis for determining the effectiveness of such nucleators as additives within polypropylene fibers.
The terms “nucleators”, “nucleator compound(s)”, “nucleating agent”, and “nucleating agents” are intended to generally encompass, singularly or in combination, any additive to polypropylene that produces nucleation sites for polypropylene crystals from transition from its molten state to a solid, cooled structure. Hence, since the polypropylene composition (including nucleator compounds) must be molten to eventually extrude the fiber itself, the nucleator compound will provide such nucleation sites upon cooling of the polypropylene from its molten state. The only way in which such compounds provide the necessary nucleation sites is if such sites form prior to polypropylene recrystallization itself. Thus, any compound that exhibits such a beneficial effect and property is included within this definition. Such nucleator compounds more specifically include dibenzylidene sorbitol types, including, without limitation, dibenzylidene sorbitol (DBS), monomethyldibenzylidene sorbitol, such as 1,3:2,4-bis(p-methylbenzylidene) sorbitol (p-MDBS), dimethyl dibenzylidene sorbitol, such as 1,3:2,4-bis(3,4-dimethylbenzylidene) sorbitol (3,4-DMDBS); other compounds of this type include, again, without limitation, sodium benzoate, NA-11, and the like. The concentration of such nucleating agents (in total) within the target polypropylene fiber is at least 100 ppm, preferably at least 1250 ppm. Thus, from about 100 to about 5000 ppm, preferably from about 500 ppm to about 4000 ppm, more preferably from about 1000 ppm to about 3500 ppm, still more preferably from about 1500 ppm to about 3000 ppm, even more preferably from about 2000 ppm to about 3000 ppm, and most preferably from about 2500 to about 3000 ppm. Furthermore, fibers may be produced by the extrusion and drawing of a single strand of polypropylene as described above, or also by extrusion of a sheet, then cutting the sheet into fibers, then following the steps as described above to draw, heat-set, and collect the resultant fibers. In addition, other methods to make fibers, such as fibrillation, and the like, are envisioned for the same purpose.
Also, without being limited by any specific scientific theory, it appears that the shrink-reducing nucleators which perform the best are those which exhibit relatively high solubility within the propylene itself. Thus, compounds which are readily soluble, such as 1,3:2,4-bis(p-methylbenzylidene) sorbitol provides the lowest shrinkage rate for the desired polypropylene fibers. The DBS derivative compounds are considered the best shrink-reducing nucleators within this invention due to the low crystalline sizes produced by such compounds. Other nucleators, such as NA-11, also provide good low-shrink characteristics to the target polypropylene fiber; however, apparently due to poor dispersion of NA-11 in polypropylene and the large and varied crystal sizes of NA-11 within the fiber itself, the shrink rates are noticeably higher than for the highly soluble, low crystal-size polypropylene produced by well-dispersed MDBS.
One manner of testing for the presence of a nucleating agent within the target fibers is preferably through differential scanning calorimetry to determine the peak crystallization temperature exhibited by the resultant polypropylene. The fiber is melted and placed between two plates under high temperature and pressure to form a sheet of sample plastic. A sample of this plastic is then melted and subjected to a differential scanning calorimetry analytical procedure in accordance with modified ASTM Test Method D3417-99 at a cooling rate of 20° C./minute. A sufficiently high peak crystallization temperature (above about 115° C., more preferably above about 116° C., and most preferably above about 116.5° C.), well above that exhibited by the unnucleated polypropylene itself, shall indicate the presence of a nucleating agent since attaining such a high peak crystallization without a nucleating agent is not generally possible.
It has been determined that the nucleator compounds that exhibit good solubility in the target molten polypropylene resins (and thus are liquid in nature during that stage in the fiber-production process) provide more effective low-shrink characteristics. Thus, low substituted DBS compounds (including DBS, p-MDBS) appear to provide fewer manufacturing issues as well as lower shrink properties within the finished polypropylene fibers themselves. Although p-MDBS is preferred, however, any of the above-mentioned nucleators may be utilized within this invention as long as the long period (SAXS) measurements are met or the low shrink requirements are achieved through utilization of such compounds. Mixtures of such nucleators may also be used during processing in order to provide such low-shrink properties as well as possible organoleptic improvements, facilitation of processing, or cost.
In addition to those compounds noted above, sodium benzoate and NA-11 are well known as nucleating agents for standard polypropylene compositions (such as the aforementioned plaques, containers, films, sheets, and the like) and exhibit excellent recrystallization temperatures and very quick injection molding cycle times for those purposes. The dibenzylidene sorbitol types exhibit the same types of properties as well as excellent clarity within such standard polypropylene forms (plaques, sheets, etc.). For the purposes of this invention, it has been found that the dibenzylidene sorbitol types are preferred as nucleator compounds within the target polypropylene fibers. Of interest, as well, is the ability to provide a purely liquid formulation of the dibenzylidene sorbitol compounds for introduction within the target polypropylene compositions. Such liquid DBS formulations comprise certain nonionic surfactants that can be selected both for their liquefying and stability-providing benefits to the DBS compounds themselves, but also potentially for their lubricating properties for the eventual fiber. In such a manner, the amount of lubricant generally required for and added to the target fiber may be reduced or eliminated, thus reducing costs associated with such additives. Thus, the surfactants required for such a liquid nucleator composition of 3,4-DMDBS (or other types of nucleating agents), include those which are nonionic and which are ethoxylated to the extent that their hydrophilic-lipophilic balance (HLB) is greater than about 8.5. HLB is a measure of the solubility of a surfactant both in oil and in water and is approximated as one-fifth (⅕) the weight percent of ethoxy groups present on the particular surfactant backbone. More specifically, such surfactants exhibit a HLB value of more preferably greater than about 12, and most preferably greater than about 13, and must possess at least some degree of ethoxylation, more preferably greater than about 4 molar equivalents of ethylene oxide (EO) per molecule, and most preferably greater than about 9.5 molar equivalents of EO per molecule.
Of these preferred surfactants, the most preferred for utilization within the potential fluid nucleating agent dispersion for purposes of this invention include, in tabulated form:
TABLE
SURFACTANT
Preferred Diluent Surfactants (with Tradenames)
Ex.
Surfactant
Available as and From
HLB #
1
sorbitan monooleate (20 EO)
Tween 80 ®;
15.0
Imperial Chemical (ICI)
2
sorbitan monostearate (20 EO)
Tween 60 ®; ICI
14.9
3
sorbitan monopalmitate (20 EO)
Tween 40 ®; ICI
15.6
4
sorbitan monolaurate (20 EO)
Tween 20 ®; ICI
16.7
5
dinonylphenol ether (7 EO)
Igepal ® DM 430;
9.5
Rhône-Poulenc (RP)
6
nonylphenol ether (6 EO)
Igepal ® CO 530; RP
10.8
7
nonylphenol ether (12 EO)
Igepal ® CO 720; RP
14.2
8
dinonylphenol ether (9 EO)
Igepal ® DM 530; RP
10.6
9
nonylphenol ether (9 EO)
Igepal ® CO 630; RP
13.0
10
nonylphenol ether (4 EO)
Igepal ® CO 430; RP
8.8
11
dodecylphenol ether (5.5 EO)
Igepal ® RC 520; RP
9.6
430
12
dodecylphenol ether (9.5 EO)
Igepal ® RC 620; RP
12.3
13
dodecylphenol ether (11 EO)
Igepal ® RC 630; RP
13.0
14
nonylphenol ether (9.5 EO)
Syn Fac ® 905;
˜13
Milliken & Company
15
octylphenol ether (10 EO)
Triton ® X-100;
13.5
Rohm & Haas
This list is not exhaustive as these are merely the preferred surfactants for use within the potential fluid nucleating agent dispersion for utilization within this invention. In such a fluid dispersion, then, the nucleating agent, such as preferably 3,4-DMDBS, comprises at most 40% by weight, preferably about 30% by weight, of the entire inventive fluid dispersion. Any higher amount will deleteriously affect the viscosity of the dispersion. Preferably the amount of surfactant is from about 70% to about 99.9%, more preferably from about 70% to about 85%; and most preferably, from about 70% to about 75% of the entire inventive fluid dispersion. A certain amount of water may also be present in order to effectively lower the viscosity of the overall liquid dispersion. Optional additives may include plasticizers, antistatic agents, stabilizers, ultraviolet absorbers, and other similar standard polyolefin thermoplastic additives. Other additives may also be present within this composition, most notably antioxidants, antistatic compounds, perfumes, chlorine scavengers, and the like. As noted above, this type of fluid dispersion is disclosed in greater detail within U.S. Pat. Nos. 6,102,999 and 6,127,440, both herein entirely incorporated by reference. Most preferred is a composition of 30% by weight of 3,4-DMDBS and 70% by weight of Tween® 80. This mixture is listed in the Preferred Embodiments section below as “Liquid 3,4-DMDBS”.
The closest prior art references teach the addition of nucleator compounds to general polypropylene compositions (such as in U.S. Pat. No. 4,016,118, referenced above). However, some teachings include the utilization of certain DBS compounds within limited portions of fibers in a multicomponent polypropylene textile structure. For example, U.S. Pat. Nos. 5,798,167 to Connor et al. and 5,811,045 to Pike, both teach the addition of DBS compounds to polypropylene in fiber form; however, there are vital differences between those disclosures and the present invention. For example, both patents require the aforementioned multicomponent structures of fibers. Thus, even with DBS compounds in some polypropylene fiber components within each fiber type, the shrink rate for each is dominated by the other polypropylene fiber components which do not have the benefit of the nucleating agent. Also, there are no lamellae that give a long period (as measured by small-angle X-ray scattering) thicker than 20 nm formed within the polypropylene fibers due to the lack of a post-heatsetting step being performed. Again, these thick lamellae provide the desired inventive higher heat-shrink fiber. Also of importance is the fact that, for instance, Connor et al. require a nonwoven polypropylene fabric laminate containing a DBS additive situated around a polypropylene internal fabric layer which contained no nucleating agent additive. The internal layer, being polypropylene without the aid of a nucleating agent additive, dictates the shrink rate for this structure. Furthermore, the patentees do not expose their yarns and fibers to heat-setting procedures in order to permanently configure the crystalline fiber structures of the yarns themselves as low-shrink is not their objective.
In addition, Spruiell, et al, Journal of Applied Polymer Science, Vol. 62, pp. 1965-75 (1996), reveal using a nucleating agent, MDBS, at 0.1%, to increase the nucleation rate during spinning. However, after crystallizing and drawing the fiber, Spruiell et al. do not expose the nucleated fiber to any heat, which is necessary to impart the very best shrinkage properties, therefore the shrinkage of their fibers was similar to conventional polypropylene fibers without a nucleating agent additive. In the examples below, yarn made with similar levels of nucleating agent additives included and no further heat exposure showed worse shrinkage (at all measured temperatures after the standard 5 minute exposure time) than commercial fibers, and fibers which contained no additive and were exposed to the same conditions. Thus, in addition to the presence of the nucleating agent additive, exposure to heat after mechanical drawing is a crucial step in the invention.
Of particular interest and which has been determined to be of primary importance in the production of such inventive low-shrink polypropylene fibers, is the discovery that, at the very least, the presence of nucleating agent within heat-set polypropylene fibers (as discussed herein), provides high long period measurements for the crystalline lamellae of the polypropylene itself. This discovery is best explained by the following:
Polymers, when crystallized from a melt under dynamic temperature and stress conditions, first supercool and then crystallize with the crystallization rate dependent on the number of nucleation sites, and the growth rate of the polymer, which are both in turn related to the thermal and mechanical working that the polymer is subjected to as it cools. These processes are particularly complex in a normal fiber drawing line. The results of this complex crystallization, however, can be measured using small angle x-ray scattering (SAXS), with the measured SAXS long period representative of an average crystallization temperature. A higher SAXS long period corresponds to thicker lamellae (which are the plate-like polymer crystals characteristic of semi-crystalline polymers like PP). The higher the crystallization temperature of the average crystal, the thicker the measured SAXS long period will be. Further, higher SAXS long periods are characteristic of more thermally stable polymeric crystals. Crystals with shorter SAXS long periods will “melt”, or relax and recrystallize into new, thicker crystals, at a lower temperature than those with higher SAXS long periods. Crystals with higher SAXS long periods remain stable to higher temperatures, requiring more heat to destabilize the crystalline structure.
In highly oriented polymeric samples such as fibers, those with higher SAXS long periods will remain stable to higher temperatures. Thus the shrinkage, which is a normal effect of the relaxation of the highly oriented polymeric samples, remains low to higher temperatures than in those highly oriented polymeric samples with lower SAXS long periods. In this invention, as is evident from these measurements, the nucleating additive is used in conjunction with a thermal treatment to create fibers with extremely high SAXS long periods of at least 20 nm, or preferably at least 22 nm, which in turn are very stable and exhibit low shrinkage up to very high temperatures.
Furthermore, such fibers may also be colored to provide other aesthetic features for the end user. Thus, the fibers may also comprise coloring agents, such as, for example, pigments, with fixing agents for lightfastness purposes. For this reason, it is desirable to utilize nucleating agents that do not impart visible color or colors to the target fibers. Other additives may also be present, including antistatic agents, brightening compounds, clarifying agents, antioxidants, antimicrobials (preferably silver-based ion-exchange compounds, such as ALPHASAN® antimicrobials available from Milliken & Company), UV stabilizers, fillers, and the like. Furthermore, any fabrics made from such inventive fibers may be, without limitation, woven, knit, non-woven, in-laid scrim, any combination thereof, and the like. Additionally, such fabrics may include fibers other than the inventive polypropylene fibers, including, without limitation, natural fibers, such as cotton, wool, abaca, hemp, ramie, and the like; synthetic fibers, such as polyesters, polyamides, polyaramids, other polyolefins (including non-low-shrink polypropylene), polylactic acids, and the like; inorganic fibers such as glass, boron-containing fibers, and the like; and any blends thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate a potentially preferred embodiment of producing the inventive low-shrink polypropylene fibers and together with the description serve to explain the principles of the invention wherein:
FIG. 1 is a schematic of the potentially preferred method of producing low-shrink polypropylene.
FIG. 2 is described in greater detail below with regard to small angle X-ray scattering and is a graphical representation of the integrated intensity data I(q) as a function of 2θ in order to determine the long period spacing of the target fibers.
FIG. 3 is also described in greater detail below with regard to small angle X-ray scattering and is a graphical representation of the K(z) function to aid in the ultimate determination of long period spacing.
DETAILED DESCRIPTION OF THE DRAWING AND OF THE PREFERRED EMBODIMENT
FIG. 1 depicts the non-limiting preferred procedure followed in producing the inventive low-shrink polypropylene fibers. The entire fiber production assembly 10 comprises an extruder 11 comprising four different zones 12 , 14 , 16 , 18 through which the polymer (not illustrated) passes at different, increasing temperatures. The molten polymer is mixed with the nucleator compound (also molten) within a mixer zone 20 . Basically, the polymer (not illustrated) is introduced within the fiber production assembly 10 , in particular within the extruder 11 . The temperatures, as noted above, of the individual extruder zones 12 , 14 , 16 , 18 and the mixing zone 20 are as follows: first extruder zone 12 at 205° C., second extruder zone 14 at 215° C., third extruder zone 16 at 225° C., fourth extruder zone 18 at 235° C., and mixing zone 20 at 245° C. The molten polymer (not illustrated) then moves into a spin head area 22 set at a temperature of 250° C. which is then moved into the spinneret 24 (also set at a temperature of 250° C.) for strand extrusion. The fibrous strands 28 then pass through a heated shroud 26 having an exposure temperature of 180° C. The speed at which the polymer strands (not illustrated) pass through the extruder 11 , spin pack 22 , and spinneret 24 is relatively slow until the fibrous strands 28 are pulled through by the draw rolls 32 , 34 , 38 . The fibrous strands 28 extend in length due to a greater pulling speed in excess of the initial extrusion speed within the extruder 11 . The fibrous strands 28 are thus collected after such extension by a take-up roll 32 (set at a speed of 370 meters per minute) into a larger bundle 30 which is drawn by the aforementioned draw rolls 34 , 38 into a single yarn 33 . The draw rolls are heated to a very low level as follows: first draw roll 34 68° C. and second draw roll 38 88° C., as compared with the remaining areas of high temperature exposure as well as comparative fiber drawing processes. The first draw roll 34 rotates at a speed of about 377 meters per minute and is able to hold fifteen wraps of the polypropylene fiber 33 through the utilization of a casting angle between the draw roll 34 and the idle roll 36 . The second draw roll 38 rotates at a higher speed of about 785 meters per minute and holds eight wraps of fiber 33 , and thus requires its own idle roll 40 . After drawing by these cold temperature rolls 34 , 38 , the fiber is then heat-set by a combination of two different heat-set rolls 42 , 44 configured in a return scheme such that eighteen wraps of fiber 33 are permitted to reside on the rolls 42 , 44 at any one time. The time of such heat-setting is very low due to a low amount of time in contact with either of the actual rolls 42 , 44 , so a total time of about 0.5 seconds is standard. The temperatures of such rolls 42 , 44 are varied below to determine the best overall temperature selection for such a purpose. The speed of the combination of rolls 42 , 44 is about 1290 meters per minute. The fiber 33 then moves to a relax roll 46 holding up to eight wraps of fiber 33 and thus also having its own feed roll 48 . The speed of the relax roll 46 is lower than the heat-set roll (1280 meters per minute) in order to release some tension on the heat-set fiber 33 . From there, the fiber 33 moves to a winder 50 and is placed on a spool (not illustrated).
Inventive Fiber and Yarn Production
The following non-limiting examples are indicative of the preferred embodiment of this invention:
Yarn Production
Yarn was made by compounding Amoco 7550 fiber grade polypropylene resin (melt flow of 18) with a nucleator additive and a standard polymer stabilization package consisting of 500 ppm of Irganox® 1010, 1000 ppm of Irgafos® 168 (both antioxidants available from Ciba), and 800 ppm of calcium stearate. The base mixture was compounded at 2500 ppm in a twin screw extruder (at 220° C. in all zones) and made into pellets. The additive was selected from the group of three polypropylene clarifiers commercially available from Milliken & Company, Millad® 3905 (DBS), Millad® 3940 (p-MDBS sorbitol), Millad® 3988 (3,4-DMDBS), two polypropylene nucleators commercially available from Asahi-Denka Chemical Company (NA-11 and NA-21), sodium benzoate, Liquid 3,4-DMDBS, and 1,3:2,4-bis(2,4,5-trimethylbenzylidene) sorbitol (2,4,5-TMDBS).
The pellets were then fed into the extruder on an Alex James & Associates fiber extrusion line as noted above in FIG. 1 . Yarn was spun with the extrusion line conditions shown in Table 1 using a 68 hole spinneret, giving a yarn of nominally 150 denier. For each additive, four yarns were spun with heat-set temperatures of 100°, 110°, 120°, and 130° C. respectively. These temperatures are the set temperatures for the controller for the rolls 42 , 44 . In practice, a variation is found to exist over the surface of the rolls 42 , 44 , up to as much as 10° C. Pellets with no nucleator additive were used to make control fibers.
The yarns were tested for shrinkage in boiling water by cutting a length of yarn, marking the ends of a “10” section with tape, placing the yarn in boiling water for 5 minutes, then taking the yarn out and measuring the length of the section between the tape marks. Measurements were taken on five pieces of each yarn, and the average change in dimension is divided by the initial length (10 inches) to give % shrinkage. Also, the measurements below have a statistical error of ±0.4 percentage units.
The yarns were similarly tested for shrinkage in hot air at 150° C. and 130° C. by marking a “10” section of yarn, placing it in an oven for five minutes at the measurement temperature, and similarly measuring the % shrinkage after removing the yarn from the oven. Again, five samples were measured, and the average shrinkage results are reported for each sample in Table 1. The shrink measurements are listed below the tested nucleators for each yarn sample. The yarn samples were as follows:
POLYPROPYLENE YARN COMPOSITION TABLE
Yarn Samples with Specific Nucleators Added
Yarn Sample
Nucleator Added
A
NA-11
B
NA-21
C
Sodium Benzoate
D
DBS
E
p-MDBS
F
3,4-DMDBS
G
Liquid 3,4-DMDBS
H
2,4,5-TMDBS
I(Comparative)
None (Control)
Fiber and Yarn Physical Analyses
These sample yarns were then tested for shrink characteristics with a number of different variables including heat-set temperatures differences (on the heat-set rolls) during manufacture and different heat-exposure conditions (hot air at various temperatures and boiling water exposure at temperatures in excess of 100° C.). The results are tabulated below:
TABLE 1
EXPERIMENTAL
Experimental Shrink Measurements for Sample Yarns
Shrinkage Test
Sample Yarn
Heatset Temp.(° C.)
and Temp.(° C.)
Shrinkage
A
100
150 Hot air
9.5%
A
110
150 Hot air
9.4%
A
120
150 Hot air
8.1%
A
130
150 Hot air
6.7%
A
100
130 Hot air
7.4%
A
110
130 Hot air
5.9%
A
120
130 Hot air
4.9%
A
130
130 Hot air
4.0%
A
100
Boiling water
4.9%
A
110
Boiling water
4.1%
A
120
Boiling water
3.6%
A
130
Boiling water
2.7%
B
100
150 Hot air
11.1%
B
110
150 Hot air
10.1%
B
120
150 Hot air
9.3%
B
130
150 Hot air
6.7%
B
100
130 Hot air
8.1%
B
110
130 Hot air
7.3%
B
120
130 Hot air
6.3%
B
130
130 Hot air
3.4%
B
100
Boiling water
5.6%
B
110
Boiling water
4.7%
B
120
Boiling water
2.7%
B
130
Boiling water
2.3%
C
100
150 Hot air
10.9%
C
110
150 Hot air
11.2%
C
120
150 Hot air
9.5%
C
130
150 Hot air
7.1%
C
100
130 Hot air
7.8%
C
110
130 Hot air
7.4%
C
120
130 Hot air
6.2%
C
130
130 Hot air
4.5%
C
100
Boiling water
6.0%
C
110
Boiling water
5.0%
C
120
Boiling water
3.9%
C
130
Boiling water
2.6%
D
100
150 Hot air
9.8%
D
110
150 Hot air
9.7%
D
120
150 Hot air
9.5%
D
130
150 Hot air
5.8%
D
100
130 Hot air
7.4%
D
110
130 Hot air
6.9%
D
120
130 Hot air
6.2%
D
130
130 Hot air
2.9%
D
100
Boiling water
5.6%
D
110
Boiling water
4.5%
D
120
Boiling water
3.1%
D
130
Boiling water
2.1%
E
100
150 Hot air
10.9%
E
110
150 Hot air
9.2%
E
120
150 Hot air
8.0%
E
130
150 Hot air
4.0%
E
100
130 Hot air
7.5%
E
110
130 Hot air
6.1%
E
120
130 Hot air
4.5%
E
130
130 Hot air
2.7%
E
100
Boiling water
4.6%
E
110
Boiling water
4.0%
E
120
Boiling water
2.4%
E
130
Boiling water
1.9%
F
100
150 Hot air
13.6%
F
110
150 Hot air
12.4%
F
120
150 Hot air
7.3%
F
130
150 Hot air
7.2%
F
100
130 Hot air
9.2%
F
110
130 Hot air
8.0%
F
120
130 Hot air
3.7%
F
130
130 Hot air
3.4%
F
100
Boiling water
6.5%
F
110
Boiling water
4.0%
F
120
Boiling water
2.6%
F
130
Boiling water
2.7%
G
100
150 Hot air
12.9%
G
110
150 Hot air
11.7%
G
120
150 Hot air
9.3%
G
130
150 Hot air
7.6%
G
100
130 Hot air
9.2%
G
110
130 Hot air
8.8%
G
120
130 Hot air
6.5%
G
130
130 Hot air
4.3%
G
100
Boiling water
6.0%
G
110
Boiling water
5.3%
G
120
Boiling water
3.9%
G
130
Boiling water
2.8%
H
100
150 Hot air
12.2%
H
110
150 Hot air
10.9%
H
120
150 Hot air
9.6%
H
130
150 Hot air
6.8%
H
100
130 Hot air
8.9%
H
110
130 Hot air
8.0%
H
120
130 Hot air
6.3%
H
130
130 Hot air
3.0%
H
100
Boiling water
5.5%
H
110
Boiling water
4.7%
H
120
Boiling water
3.3%
H
130
Boiling water
2.1%
I
100
150 Hot air
21.3%
I
110
150 Hot air
19.3%
I
120
150 Hot air
17.4%
I
130
150 Hot air
13.4%
I
100
130 Hot air
12.5%
I
110
130 Hot air
10.7%
I
120
130 Hot air
8.6%
I
130
130 Hot air
5.3%
I
100
Boiling water
6.8%
I
110
Boiling water
5.2%
I
120
Boiling water
3.2%
I
130
Boiling water
3.2%
In addition, two commercial yarns were obtained from Filament Fiber Technology and tested in each of the three tests, with the results shown in Table 3. Commercial Yarn #1 is an air jet textured yarn with a black pigment. Commercial Yarn #2 is an air jet textured yarn with a white pigment.
TABLE 2
EXPERIMENTAL
Experimental Data for Comparative Commercial Polypropylene Yarns
Test
Comm. Yarn #1
Comm. Yarn #2
150° C. Hot air shrinkage
13.0%
12.1%
130° C. Hot air shrinkage
7.8%
7.0%
Boiling water shrinkage
4.8%
5.5%
It is evident from these two TABLEs that the inventive polypropylene yarns (including those made from the inventive method described above) exhibit vastly improved shrinkage rates for all three test methods and thus are clearly improvements over the commercially available prior art yarns as well as those yarns lacking nucleating agent and heat-set.
Additive Level Dependence
To test the dependence on nucleator additive level, additional yarns were spun in accordance with the method described above with varying levels of additive using Amoco 7550 resin. The additive was compounded into the resin and the fibers spun under the same conditions as in the previous examples. The yarns were similarly tested, with the results shown in Table 5.
TABLE
POLYPROPYLENE YARN SAMPLE
Yarn Samples with Specific Nucleators Added
Yarn Sample
Nucleator Added (Amount ppm)
J
NA-11 (1000)
K
3,4-DMDBS (1250)
L
2,4,5-TMDBS (1250)
TABLE 3
EXPERIMENTAL
Experimental Data for Different Nucleator Levels in Polypropylene Yarns
Shrinkage Test
Sample Yarn
Heatset Temp.(° C.)
and Temp.(° C.)
Shrinkage
J
100
150 Hot air
18.1%
J
110
150 Hot air
16.6%
J
120
150 Hot air
16.7%
J
130
150 Hot air
9.0%
J
100
130 Hot air
10.4%
J
110
130 Hot air
9.0%
J
120
130 Hot air
6.8%
J
130
130 Hot air
4.5%
J
100
Boiling water
5.4%
J
110
Boiling water
4.8%
J
120
Boiling water
3.3%
J
130
Boiling water
2.6%
K
100
150 Hot air
15.7%
K
110
150 Hot air
17.1%
K
120
150 Hot air
13.0%
K
130
150 Hot air
8.8%
K
100
130 Hot air
9.3%
K
110
130 Hot air
8.6%
K
120
130 Hot air
5.5%
K
130
130 Hot air
4.0%
K
100
Boiling water
6.8%
K
110
Boiling water
4.5%
K
120
Boiling water
3.3%
K
130
Boiling water
2.5%
L
100
150 Hot air
16.9%
L
110
150 Hot air
15.8%
L
120
150 Hot air
13.2%
L
130
150 Hot air
8.7%
L
100
130 Hot air
11.1%
L
110
130 Hot air
9.2%
L
120
130 Hot air
6.8%
L
130
130 Hot air
4.5%
L
100
Boiling water
6.8%
L
110
Boiling water
4.3%
L
120
Boiling water
3.3%
L
130
Boiling water
2.3%
Thus, additive levels are important to providing overall good low shrinkage characteristics for the target polypropylene yarns. Higher levels appear to provide better shrinkage properties.
X-Ray Scattering Analysis
The long period spacing of several of the above yarns was tested by small angle x-ray scattering (SAXS). The small angle x-ray scattering data was collected on a Bruker AXS (Madison, Wis.) Hi-Star multi-wire detector placed at a distance of 105 cm from the sample in an Anton-Paar vacuum chamber where the chamber was evacuated to a pressure of not more than 100 mTorr. X-rays (λ1.54178 Å) were generated with a MacScience rotating anode (40 kV, 40 mA) and focused through three pinholes to a size of 0.2 mm. The entire system (generator, detector, beampath, sample holder, and software) is commercially available as a single unit from Bruker AXS. The detector was calibrated per manufacturer recommendation using a sample of silver behenate.
A typical data collection was conducted as follows. To prepare the sample, the yarn was wrapped around a 3 mm brass tube with a 2 mm hole drilled in it, and then the tube was placed in an Anton-Paar vacuum sample chamber on the x-ray equipment such that the yarn was exposed to the x-ray beam through the hole. The path length of the x-ray beam through the sample was between 2-3 mm. The sample chamber and beam path was evacuated to less than 100 mTorr and the sample was exposed to the X-ray beam for one hour. Two-dimensional data frames were collected by the detector and unwarped automatically by the system software. The data were smoothed within the system software using a 2-pixel convolution prior to integration. To obtain the intensity scattering data [I(q)] as a function of scattering angle [2θ] the data were integrated over ø with the manufacturer's software set to give a 2θ range of 0.2°-2.5° in increments of 0.01° using the method of bin summation. These raw scattering data were then transformed into a real space correlation function K(z) using a FORTRAN program written in house to evaluate the integral: K ( z ) = ∫ 0 ∞ 4 π q 2 I ( q ) cos ( 2 π q z ) q where q = 4 πsin ( θ ) / λ .
The integral was evaluated by direct summation over all values 2θ in the data range (0.2°-2.50) and over the real space values from 0 nm-50 nm. This follows the method of G. Strobl (Strobl G. The Physics of Polymers; Springer: Berlin 1997, pp. 408-14), entirely incorporated by reference. From the one-dimensional correlation function, K(z), one can extract the morphological data of interest, in this case long period spacing (L). The integrated intensity data I(q) as a function of 2θ demonstrates a broad hump corresponding to the long period spacing (FIG. 2 ). The K(z) function has a characteristic shape (FIG. 3 ). The relevant extractable data points are indicated. Long-period spacing is extracted from K(z) data as the global maximum of the function occurring at a higher z value than the global minimum.
These data are collected in Table 6. Also included in Table 6 are the measurements as a result of 150° C. hot air exposure (to test for shrinkage). As can be clearly seen, a longer SAXS long period corresponds to a lower shrinkage. In addition, samples prepared with the additive, but without sufficient heat in the process (represented in this case by a 130° C. heatset), gave a smaller SAXS long period and a correspondingly higher 150° C. hot air shrinkage. The following TABLE thus shows the correlation between SAXS long period measurements with 150° C. hot air exposure (for shrinkage of the target yarns), as well as the correlation between heat-set temperatures with such characteristics.
TABLE 4
EXPERIMENTAL
SAXS and 150° C. Hot Air Shrinkage Data For Yarn Samples
Sample Yarn
Heat-set Temp. (° C.)
Shrinkage
SAXS Long Period
A
130
6.7%
26.45
B
130
6.7%
22.35
C
130
7.1%
21
D
130
5.8%
23.2
E
130
4.0%
26.4
E
120
8.0%
21
E
110
9.2%
18.4
F
130
7.2%
21.55
H
130
6.8%
22.4
Comm. Yarn 1
—
12.1%
16.95
Comm. Yarn 2
—
13.0%
15.6
It is thus evident that the higher the long period as measured by small-angle X-ray scattering, the lower the shrinkage exhibited by the target polypropylene yarn.
Peak Crystallization Temperatures
As noted above, in order to provide the desired low-shrink characteristics to the target yarns and/or fibers, a nucleating agent should be added. Although the presence of a nucleating agent or agents is necessary to accord such low-shrink properties in tandem with a proper heat-setting of the fiber and/or yarn, it is not a requirement that all nucleating agents present within the target yarn and/or fiber exhibit a relatively high peak crystallization temperature. There are certain instances, however, wherein the nucleating agent does induce such high peak crystallization temperatures and thus their presence may be determined through differential scanning calorimetry analysis. For those nucleating agents that do not induce the target polymer to exhibit such high peak crystallization temperatures, other methods of analysis (gas chromatography/mass spectroscopy, as one example) may be utilized to determine their presence. For example, although sodium benzoate is well known as a polyolefin nucleating agent (as defined above), peak crystallization results within polypropylene yarns and/or fibers are not consistent with accepted results for sodium benzoate within other types of polypropylene articles (such as plaques, containers, and the like). Some peak crystallization measurements for sodium benzoate within polypropylene fibers have been nearly as low as the measurements for the polypropylene itself. Again, since sodium benzoate provides effective low-shrink characteristics for such fibers and/or yarns, the lack of high peak crystallization temperatures for such sodium benzoate-containing polypropylene fiber samples does not remove sodium benzoate from the definition of nucleating agent for the purposes of this invention.
Thus, for the polypropylene samples including the remaining types of nucleating agents, peak crystallization was measured by the following method (a modified version of ASTM D3417-99 including a manner of creating a proper measurable sample of the test fibers themselves): A Perkin-Elmer DSC7 calibrated with an indium metal standard at a heating rate of 20° C./min was used to measure the peak crystallization temperature of the polypropylene fibers. Bundles of polypropylene fibers were heated to 220° C. for 1 minute and then compressed into thin disks approximately 250 μm thick. The specific polyolefin/DBS mixture composition was heated from 60° C. to 220° C. at a rate of 20° C. per minute to produce a molten formulation and held at the peak temperature for 2 minutes. At that time, the temperature was then lowered at a rate of 20° C. per minute until it reached the starting temperature of 60° C. The peak crystallization temperature of the polymer was thus measured as the peak maximum during the crystallization exotherm. This entire procedure of first preparing fibers into plaques followed by DSC analysis in accordance with the modified ASTM D-3417-99 test is herein referred to as “fiber peak crystallization temperature measurement(s)” for the purposes of this invention. The results for the fiber peak crystallization temperature measurements for the samples from Table 1, above, are tabulated below (with a standard deviation of ±0.5° C.):
TABLE 5
EXPERIMENTAL
Peak Crystallization Temperatures For Yarn Samples
Peak Crystallization
Sample Yarn
Heat-set Temp. (° C.)
Temperature (Tc)(° C.)
A
120
124.3
B
130
124.6
D
130
117.0
E
130
123.7
F
130
124.5
H
130
122.2
I(Comparative)
130
109.9
Thus, the presence of certain nucleating agents provided relatively high peak crystallization temperatures for the sample yarns (at least above 115° C., and as high as a low level of about 117.0° C.).
Fabric Article Production and Analyses
Woven Fabric Comprising the Inventive Yarn
Fabric was woven using the inventive yarns and a 150 denier, 34 filament polyester warp, and weaving a square weave with 84 picks/inch using five yarns: a control made as above with no additive with final draw roll 3 A and 3 B temperatures of 110° C. and 130° C. Three experimental yarns were made having 2500 ppm 3,4-DMDBS (Sample yarns F, from above) and a final draw roll 3 A and 3 B temperature of 110° C., 130° C., and 140° C. respectively. These sample fabrics were separated into 18 inch squares. A 12″ box was drawn in the center of the piece of fabric, and the fabric was washed five times in either hot (60° C.) or cold (20° C.) water, and dried for 30 minutes in a conventional dryer (at about 70° C. for 20 minutes). The dimensional change of the 12″ box was measured, and is reported in Table 6 as % shrinkage.
TABLE 6
EXPERIMENTAL
Fabric Sample Shrinkage Data
Sample Fabric
(corresponding
Yarn Heat-set
Cold Wash
Hot Wash
to TABLE 1, above)
Roll Temp. (° C.)
Shrinkage
Shrinkage
F
110
2.4%
5.8%
F
130
2.9%
3.7%
F
140
2.4%
3.7%
I(Comparative)
110
8.9%
14.9%
I(Comparative)
130
5.0%
6.8%
Thus, it is evident that the fabric samples comprising the inventive yarns exhibit lower shrinkage rates as well.
Knit Fabric Construction Comprising the Inventive Yarn
Yarns from TABLE 1 were produced with a heat-set roll temperature of 130° C. and were subsequently knit into socks on a Lawson Hemphill FAK Knitter 36 gage knitting machine using 160 needles (needle no. 71.70) at speed setting 4 using 40 PSI of air pressure. The fabric was laid flat, and a 2.75″×10″ section of sock was marked (10″ in the course direction, 2.75″ in the wales direction). The socks were placed in an oven at 150° C. (hot air) for five minutes, and then the dimensions of the marked section were measured. The shrinkage in each direction and the area shrinkage are reported in TABLE 8, below. The area shrinkage is the product of the measured dimensions (the area) divided by 27.5 sq. inches (the original area), reported as a percentage.
TABLE 7
EXPERIMENTAL
150° C. Hot Air Shrinkage Data For Knit Fabric Samples
Sample Yarn
Course Shrinkage
Wales Shrinkage
Area Shrinkage
A
5.3%
2.8%
8.0%
B
7.2%
2.8%
9.8%
C
8.8%
2.2%
10.8%
D
0.6%
3.4%
4.0%
E
1.6%
1.6%
3.2%
F
5.6%
2.8%
8.2%
H
7.2%
2.2%
9.2%
I(Comparative)
11.3%
4.4%
15.2%
Comm. Yarn 1
20.6%
5.3%
24.8%
Comm. Yarn 2
20.0%
3.8%
23.0%
Therefore, it is evident that the inventive knit fabrics exhibit far better shrinkage characteristics than the commercial yarn-containing fabric samples as well as the control without any nucleator compound present. The control yarn gave very high area shrinkage, which was eclipsed by the air jet textured commercial yarns. Yarns with DBS and p-MDBS gave very low shrinkage, easily acceptable within the apparel industry.
Non-Woven Fabric Construction Comprising the Inventive Yarn
Yarns from Sample E of TABLE 1 were produced with a heat-set roll temperature of 130° C. and were extruded at a pump rate of 87.6 cc/min with a 68 hole spinneret, to give a total yarn denier of 680 and a denier per filament of 10. The fibers were combined by plying such into 5 yarns of 2720 denier, which were then combined into a single tow of 13600 denier, which was heated at ˜90° C. in steam, crimped in a stuffer box, and then cut to a staple length of 3.25 inches. The staple was then carded, lapped using a Fiber Locker manufactured by James Hunter Machine Company, and then needled with a Di-Lour-6 manufactured by Dilo, Inc. into a bat approximately 12×24 inches. Boxes of 130.3 cm 2 were marked on the bat. The bat was then molded by heating with an IR lamp for 60 seconds to temperatures reaching 120-150° C. and then compressing in a 10° C. mold. The boxes showed average shrinkage of 3.2%.
A control yarn of 10 DPF with no additive was obtained. It was then crimped and cut into staple, carded, lapped, and needled in the same manner. Boxes were again marked prior to molding. When molded under the same conditions, the boxes showed an average shrinkage of 11.7%.
It is thus evident that the non-woven fabrics made from the inventive low-shrink propylene yarns also exhibit excellent low-shrink characteristics in comparison with control samples.
There are, of course, many alternative embodiments and modifications of the present invention which are intended to be included within the spirit and scope of the following claims. | Improved polypropylene fibers exhibiting greatly reduced heat- and moisture-shrink problems and including certain compounds that quickly and effectively provide rigidity to the target polypropylene fiber after heat-setting are disclosed herein. In such a manner, the “rigidifying” compounds provide nucleation sites for polypropylene crystal growth. After drawing the nucleated composition into fiber form, the fiber is then exposed to sufficient heat to grow the crystalline network, thus holding the fiber in a desired position. The preferred “rigidifying” compounds include dibenzylidene sorbitol based compounds, as well as less preferred compounds, such as sodium beuzoate, certain sodium and lithium phosphate salts (such as sodium 2,2′-methylene-bis-(4,6-di-tert-butylphenyl)phosphate, otherwise known as NA-11). | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation in part of application Ser. No. 10/117,556, filed Apr. 3, 2002, now abandoned.
GOVERNMENT INTEREST
The invention described here may be made, used and licensed by and for governmental purposes without paying me any royalty.
BACKGROUND OF THE INVENTION
1. Field of the Invention
In one aspect this invention relates to armored vehicles. In a further aspect this invention relates to a transparent armor structure useful in military and security vehicles. In yet a further aspect, this invention relates to architectural structures for security purposes.
2. Prior Art
Security has become increasingly important. With respective to vehicle structures in general, military vehicles require greater than average protection for the occupants. This has given rise to various transparent armor structures for windshields and side windows that are designed to resist the incursion of small arms projectiles and shrapnel. This work has been ongoing for many years. In constructing transparent armor, “bullet proof glass”, sandwiches made from tempered glass, and plastic layers are bonded together to form complex laminated composites all the. The resulting composites must be transparent and free of optical distortion while maximizing the ballistic protection from penetrators. In use, the inner and out of layers of the composite will be subjected to shock, scratching, abrasion and adverse weather conditions, particularly when a transparent armor composite is used in military applications.
The various layers used in the composite are chosen for their different projectile resisting characteristics and functions. For example, glass layers are hard and thus readily erode bullets and are highly abrasion resistant. However, glass layers are brittle which causes any glass layers opposite a penetration threat to spall, which in turn creates shrapnel fragments. The shrapnel creates numerous projectiles upon the interior surface of the vehicle and the resulting spall or fragments can be more dangerous than the original penetrator. Plastic material layers used as part of a composite sandwich provide a means to introduce flexibility into the transparent armor composite. The addition of one more plastic layers to the composite changes the failure mode of the transparent armor so it fails in a more ductile manner rather than spalling. Acrylic, polyurethane and polycarbonate based materials are among the polymeric materials which have been shown to have utility in making transparent armor composites.
One example of a transparent sheet composite useful as transparent armor is shown in U.S. Pat. No. 5,506,051. This particular patent discloses a laminated glass and polycarbonate construction with the addition of one or more transition layers of cured aliphatic urethane. The urethane provides a tension absorbing transmission layer within the composite. This patent also describes glasses and plastic materials useful in forming laminates that can be used as transparent armor.
One class of plastics that has proven both useful and reliable in constructing transparent armor composites and architectural bandit type barriers is polycarbonate. Polycarbonate has proved to have superior characteristics in terms of providing overall protection because it is the plastic with the highest spread between brittleness transition temperature and heat distortion temperature. This makes polycarbonates generally preferred materials in transparent armor composites. Unfortunately, polycarbonate and the other useful plastic materials useful in the practice of this invention are soft and easily abraded by the action of dirt and dust. Further, these materials are frequently adversely affected by solvents and cleaning solutions when used to remove dirt. Thus, if plastics are used as the inner layer of a transparent armor composite, cleaning the surface dirt and grime will inevitably cause scratching. This causes the optical properties to be adversely effected. The scratching can cause the transparency of the transparent armor composite to substantially degrade in under one year. The substantial degradation of transparency necessitates replacement of the composite. Since the transparent armor composites are expensive, frequent replacement creates a substantial financial burden on maintenance budgets.
It appeared the only alternative to a degrading composite was to have an innermost glass layer. This carries an increased spalling risk. The transparent armor assembly of the present invention provides a system with separate, parallel elements combined in a basic structure. The first element is a transparent armored composite that can defeat a penetrator and has an outer layer which withstands the abrasion of the ambient environment outside the vehicle. The second element is located between the first element and the vehicle's interior, removed from the first element so that the shock of the penetrator is absorbed by the first element and is not transmitted to the second element. This structure allows the use of a sacrificial inner element which permits cleaning without degradation of the expensive portion of the structure while providing a good spall retaining to inner layer. As an added advantage, the second element of this invention is easily changed so we can easily switch from a heat limiting sun screen to a clear screen compatible with night vision devices. This allows enhanced daytime operation without adversely affecting nighttime operation
SUMMARY OF THE INVENTION
Briefly the present invention is an improved transparent armor structure for use in protecting an opening in a vehicle. The armor structure includes a multipart C-shaped frame mounted to a vehicle, the frame surrounding the opening. The frame is adapted to firmly hold a sheet of laminated transparent armor composite. The laminated armor composite has inner and outer layers of tempered silica glass material. The laminated armor composite has at least one layer of a polymeric material, such as polycarbonate, integrally bonded with the layers of tempered silica glass. The laminated armor composites useful in practicing this invention will comprise at least three layers integrally bonded to form a laminated bullet resisting structure. The bonding adhesives and other consolidating materials are chosen so that the composite is optically clear and non-yellowing. Of course, the laminated armor composite can be more than three lamellas thick. In constructing the laminated armor composite the various lamella are chosen from among assorted transparent materials chosen for their unique projectile resistance and flexibility characteristics.
The C-shaped frame that encloses the transparent armor composite is attached to the vehicle and extends into the vehicle interior. The C-shaped frame supports the transparent armor composite and associated parts of the structure in place. A y-shaped member is attached to the C-shaped frame, the y-shaped member being adapted to hold a freestanding transparent spall resisting layer parallel to and spaced from the innermost surface of the transparent armor composite. The y-shaped member is positioned on the inside of the vehicle and attached to the C-shaped frame in a manner to allow easily removal and replacement of the spall layer.
The spall layer can be formed from a transparent material generally chosen from the types of material used in the transparent armor composite. While the spall layer can be scratched, or otherwise adversely affected by cleaning solvents and abrasives, it can be easily and inexpensively replaced. The separation between the spall resistant layer and the transparent armor composite protects the spall resistant layer from shock waves induced in the transparent armor by penetrators. Also, having the spall resistant layer separately mounted and easily changed allows the spall resistant layer to have a sunshade or other optical coating suitable for daytime operation while allowing the spall resistant layer to be easily changed for nighttime operation.
A spacing means is located between the transparent armor composite and the spall resisting layer along their edges to form a chamber. The chamber contains a desiccant to minimize or eliminate the amount of moisture within the chamber so as to control any condensation, which would create an impediment to vision.
BRIEF DESCRIPTION OF THE DRAWING
In the accompanying drawing:
The FIGURE is a partial side view in section of one embodiment of this invention.
DETAILED DESCRIPTION
Referring to the accompanying drawing, an improved transparent armor structure according to this invention is designated generally as 10 . A transparent laminated armor composite 12 is shown with a plurality of lamella. Tempered silica glass lamella 14 , 16 form the innermost and outermost layers of the composite. The tempered silica glass provides ballistic strength and abrasion resistance to the transparent armor. Silica glass is also highly resistant to common chemicals which can attack and degrade the transparency of the armor composite if plastic layers are exposed to the chemicals. Using silica glass as the outer layers allows the present transparent armor composite 12 to be cleaned using solvents or abrasive cleaners without substantial degradation of optical properties. The glass lamella 14 , 16 each have a layer of plastic material 18 , 20 laminated to their inner surfaces. As shown and as is common in transparent laminated armor composites 12 there are additional inner layers of material 22 , 24 and a central layer 26 . These inner layers will generally be additional layers of tempered glass and energy absorbing layers of plastic material or similar strengthening materials designed to absorb shock and provide the composite with additional penetration resistance. The particular materials chosen for the inner layers 22 , 24 , and 26 will be chosen based on the particular threat expected. The materials useable for inner layers 22 , 24 and 26 are generally known in the transparent armor art and the material of choice and thickness will be dictated by threat protection, weight allowance, optical properties, manufacturing considerations and cost considerations. The innermost 14 and outer most layer 16 used in the present transparent laminated armor 12 are tempered silica glass since that is the material which provides the greatest resistance to scratching and chipping and thus is the most desirable material on the outermost surfaces of the transparent laminated armor 12 composite to preserve and maintain optical integrity. The choice of particular materials for each individual lamella within the transparent laminated armor composite 12 is within the skill of the art and further description is omitted in the interest of brevity.
The transparent laminated armor 12 is mounted in a multi-part C-shaped frame 30 attached to a vehicle, not shown. The multiplied-part C-shaped frame 30 surrounds and encloses the edge of the transparent laminated armor composite's 12 . The multi-part C-shaped frame 30 is formed to securely mount the transparent laminated armor composite 12 in position over an opening in the vehicle normally a vehicle window or windshield. In the multi-part C-shaped frame 30 shown, a first leg 32 forms one side of the C-shape of the frame and extends vertically beyond the frame's lower boundary so as to provide a flange 34 . Flange 34 has a first plurality of apertures 35 that allow the flange to be attached to the vehicle's frame 36 surrounding the opening to be protected.
The flange 34 is secured to the vehicle frame 36 using a first plurality of threaded fasteners 38 passing through the first plurality of apertures 35 . The threaded fasteners 38 are disposed at intervals around the periphery of the vehicle opening to provide proper support about circumference of the opening. The first vertical leg 32 of frame 30 is attached to a horizontal member 40 extending orthogonally from the first vertical leg into the vehicle's interior. As shown, first vertical leg 32 is firmly secured to horizontal member 40 by a second plurality of threaded fasteners 42 passing apertures 43 in the first vertical leg 32 and engaging a mating threaded aperture in the horizontal member. At the opposite and of the horizontal member 40 , distal the first vertical leg 32 is a second vertical leg 44 . The second vertical leg 44 is held in place on the horizontal member by a third plurality of threaded fasteners 46 passing through the second vertical leg 44 and engaging complementary threaded apertures in the horizontal member 40 . The resulting C-shaped frame structure 30 surrounds and holds the transparent laminated armor composite 12 in position and allows it to be secured about the periphery of the vehicle opening so as to cover the opening and protect the vehicle's interior.
As noted before, silica glass while having good strength and abrasion resistance is brittle and the shock wave set up in transparent armor by the incursion of a projectile will cause fracture and spalling. This may happen when the edges of the transparent laminated armor 12 are exposed to chipping and stressing even absent projectile incursion. Therefore, to protect the transparent laminated armor 12 edge and provide a seal, a shaped polymeric gasket 48 is disposed between the transparent laminated armor composite 12 and the C-shaped frame 30 . The gasket 48 can be formed of various natural or synthetic polymeric sealing materials that will serve to seal the transparent laminated armor composite 12 image.
Because the transparent laminated armor composite 12 of this invention has silica glass layers as the innermost and outermost lamella 14 , 16 to provide abrasion resistance, any spall over fragments created by the shock wave of a projectile incursion, must be retained. The, the structure of this invention provides full protection by means of a y-shaped bracket designated generally 50 , which holds a transparent spall resisting pane 52 parallel to and slightly spaced from the inner lamella 16 of the transparent laminated armor composite 12 , the spall resisting pane being positioned on the inside face of the transparent laminated armor when mounted on the vehicle. The y-shaped bracket 50 and spall resisting pane 52 operate is a unit which allows easy removal and replacement of the spall resisting plate. The y-shaped bracket 50 is attached to the C-shaped bracket 30 using the third set of threaded fasteners 46 which allows easy removal of the spall resisting pane 52 . Removal makes it easy to clean the inner surface of the transparent laminated armor composite 12 as needed. When it is necessary to replace the spall resisting pane 52 due to scratching or discoloration, a new pane can be substituted at cleaning. The spall resisting pane 52 can be formed from the same types of plastic materials as the flexible ballistic layers in the transparent laminated armor composite 12 , for example, polycarbonate or acrylic materials. Thus even if the spall pane 52 is subject to scratching, and can be adversely effected by cleaning with solvents and abrasive cloths, once the spall pane 52 has deteriorated a new one is easily installed. The expense of changing a spall plate 52 is minimal as compared to replacing the entire composite 12 that is many times more expensive just in material costs.
Placing the spall resisting pane 52 spaced from the transparent armor composite 12 protects the spall resistant pane 52 from the shock wave generated by the incursion of the penetrator. Because the spall resistant pane 52 is not subject to the shock wave it can also be made of tempered glass. The ease of replacement also allows a sunscreen glass or plastic to be used as the spall resistant plate 52 on sunny days and replaced with a transparent sheet at night or on overcast days.
The second vertical leg 44 of C-shaped bracket 30 acts as a spacer between the composite 12 and the spall pane 52 forming a chamber 54 which protects the spall resistant plate 52 from shock waves and collects spall. The chamber 54 has a desiccant 56 disposed within the chamber, the desiccant serving to minimize or eliminate the moisture within the chamber to control the condensation. Condensation on surfaces will interfere with vision and results in safety problems. The easy removal ability of the y-shaped bracket, spall resistant pane 52 unit will allow the desiccant 56 to be rapidly replaced when it becomes saturated.
Various alterations and modifications will become apparent to those skilled in the art without departing from the scope and spirit of this invention and it is understood this invention is limited only by the following claims. | An improved transparent armor structure for use in a vehicle includes a first sheet of transparent armor composite comprising at least one layer of polymeric material and at least one layer of tempered silica glass bonded to form a laminated bullet resisting structure and also having a bracket member adapted to hold a second transparent spall resisting layer parallel to and slightly spaced from the inner surface of the first transparent composite layer. A spacing means between the first and second layers forms a chamber between the first and second panels and a desiccant is located within the chamber to minimize the amount of condensation on the surface of the transparent armor surfaces. | 5 |
FIELD OF THE INVENTION
This invention relates to benzobicyclic substituted carboxamide compounds which exhibit 5-HT 3 antagonist properties including CNS, anti-emetic and gastric prokinetic activity and which are void of any significant D 2 receptor binding affinity. This invention also relates to pharmaceutical compositions and methods for the treatment of gastrointestinal and mental disorders using said compounds.
5-Hydroxytryptamine, abbreviated "5-HT", is commonly known as serotonin. Serotonin is found throughout the body including the gastrointestinal tract, platelets, spleen and brain, appears to be involved in a great number of physiological processes such as neurotransmission at certain neurones in the brain, and is implicated in a number of central nervous system (CNS) disorders. Additionally, serotonin appears to act as a local hormone in the periphery; it is released in the gastrointestinal tract, where it increases small intestinal motility, inhibits stomach and colon motility, and stimulates stomach acid production. Serotonin is most likely involved in normal intestinal peristalsis.
The various physiological activities exerted by serotonin are related to the variety of different receptors found on the surface membrane of cells in different body tissue. The first classification of serotonin receptors included two pharmacologically distinct receptors discovered in the guinea pig ileum. The "D" receptor mediates smooth muscle contraction and the "M" receptor involves the depolarization of cholinergic nerves and release of acetylcholine. Three different groups of serotonin receptors have been identified and the following assignment of receptors has been proposed: D-receptors are 5-HT 2 -receptors; M-receptors are termed 5-HT 3 -receptors; and all other receptors, which are clearly not 5-HT 2 or 5-HT 3 , should be referred to as 5-HT 1 -like.
5-HT 3 -receptors have been located in non-neurological tissue, brain tissue, and a number of peripheral tissues related to different responses. It has been reported that 5-HT 3 -receptors are located on peripheral neurones where they are related to serotonin's (excitatory) depolarizing action. The following subtypes f 5-HT 3 receptor activity have been reported: action involving postganglionic sympathetic and parasympathetic neurones, leading to depolarization and release of noradrenaline and acetylcholine, respectively (5-HT 3B subtype); action on enteric neurones, were serotonin may modulate the level of acetylcholine (5-HT 3C subtype); and action on sensory nerves such as those involved in the stimulation of heart nerve endings to produce a reflex bradycardia (5-HT 3A subtype), and also in the perception of pain.
Highly selective 5-HT 3 -antagonists have been shown to be very effective at controlling and preventing emesis (vomiting) induced by chemotherapy and radiotherapy in cancer patients. The anti-emetic effects of 5-HT 3 -antagonists in animals exposed to cancer chemotherapy or radiation are similar to those seen following abdominal vagotomy. The antagonist compounds are believed to act by blocking 5-HT 3 -receptors situated on the cell membranes of the tissue forming the vagal afferent input to the emetic coordinating areas on the brain stem.
Serotonin is also believed to be involved in the disorder known as migraine headache. Serotonin released locally within the blood vessels of the head is believed to interact with elements of the perivascular neural plexus of which the afferent, substance P-containing fibers of the trigeminal system are believed relevant to the condition. By activating specific sites on sensory neuronal terminals, serotonin is believed to generate pain directly and also indirectly by enhancing the nociceptive effects of other inflammatory mediators, for example bradykinin. A further consequence of stimulating the afferent neurones would be the local release of substance P and possibly other sensory mediators, either directly or through an axon reflex mechanism, thus providing a further contribution to the vascular changes and pain of migraine. Serotonin is known to cause pain when applied to the exposed blister base or after an intradermal injection; and it also greatly enhances the pain response to bradykinin. In both cases, the pain message is believed to involve specific 5-HT 3 receptors on the primary afferent neurones.
5-HT 3 -antagonists are also reported to exert potential antipsychotic effects, and are believed to be involved in anxiety. Although not understood well, the effect is believed to be related to the indirect blocking of serotonin 5-HT 3 -mediated modulation of dopamine activity.
Many workers are investigating various compounds having 5-HT 3 -antagonist activity.
REPORTED DEVELOPMENTS
The development of 5-HT 3 agents originated from work carried out with metoclopramide (Beecham's Maxolon, A. H. Robins' Reglan), which is marketed for use in the treatment of nausea and vomiting at high doses. Metoclopramide is a dopamine antagonist with weak 5-HT 3 -antagonist activity, which becomes more prominent at higher doses. It is reported that the 5-HT 3 activity and not the dopamine antagonism is primarily responsible for its anti-emetic properties. Other workers are investigating this compound in connection with the pain and vomiting accompanying migraine.
Merrell Dow's compound MDL-72222 is reported to be effective as an acute therapy for migraine, but toxicity problems have reportedly ended work on this compound. Currently four compounds, A. H. Robin' Zacopride, Beecham's BRL-43694, Glaxo's GR-38032F and Sandoz' ICS-205-930 are in clinical trials for use in chemotherapy-induced nausea and vomiting. GR-38032F is also in clinica trials in anxiety and schizophrenia, and reportedly, Zacopride in anxiety, while ICS-205-930 has been shown to be useful in treating carcinoid syndrome.
Compounds reported as gastroprokinetic agents include Beecham's BRL-24924, which is a serotonin-active agent for use in gut motility disorders such as gastric paresis, audition reflux esophagitis, and is know to have also 5-HT 3 -antagonist activity.
Metoclopramide, Zacopride, Cisapride and BRL-24924 are characterized by a carboxamide moiety situated para to the amino group of 2-chloro-4-methoxy aniline. BRL-43694, ICS-205930, GR-38032F and GR-65630 are characterized by a carbonyl group in the 3-position of indole or N-methyl indole. MDL-72222 is a bridged azabicyclic 3,5-dichlorobenzoate, while Zacopride, BRL-24924, BRL-43694 and ICS-205930 have also bridged azabicyclic groups in the form of a carboxamide or carboxylic ester.
Bicyclic oxygen containing carboxamide compounds wherein the carboxamide is ortho to the cyclic oxygen moiety are reported to have antiemetic and antipsychotic properties in EPO Publ. No. 0234872.
Dibenzofurancarboxamides and 2-carboxamide-substituted benzoxepines are reported to have 5HT 3 -antagonist and gastroprokinetic activity in copending application Ser. Nos. 152,112, 152,192, and 168,824, all of which are assigned to the same assignee as the present application.
SUMMARY OF THE INVENTION
This invention relates to benzobicyclic carboxamide compounds having 5-HT 3 antagonist activity. Preferred compounds of this invention are of the formula ##STR1## wherein: X is hydrogen, alkyl, alkoxy, hydroxy, amino, mono- and di-alkylamino, halo, trifluoromethyl, nitro, sulfamyl, mono- and di-alkylsulfamyl, alkylsulfonyl, carboxy, carbalkoxy, carbamyl or mono- and di-alkylcarbamyl;
Y is hydrogen, alkyl, alkenyl, aralkyl, ##STR2## Z is ##STR3## 3-quinuclidine, 4-quinuclidine, 4-(1-azabicyclo[3.3.1]nonane), 3-(9-methylazabicyclo[3.3.1]-nonane), 7-(3-oxo-9-methylazabicyclo[3.3.1]nonane) or 4-[3-methoxy-1-(3-[4-fluorophenoxy]propyl) piperidine];
R 1 , R 2 , R 3 and R 4 are independently hydrogen or alkyl;
vicinal R 2 groups may together form a carbocyclic ring;
vicinal R 1 rous may form a double bond;
a and b are 1 to 4;
n is 1 to 3;
and pharmaceutically acceptable salts thereof.
This invention related also to pharmaceutical compositions including an effective therapeutic amount of the aforementioned benzobicyclic carboxamide compound and therapeutic methods for the treatment of a patient suffering from gastrointestinal and/or psychochemical imbalances in the brain by administering said pharmaceutical composition.
Another aspect of the present invention relates to a process for the preparation of the above-described compounds.
DETAILED DESCRIPTION
As employed above and throughout the disclosure, the following terms, unless otherwise indicated, shall be understood to have the following meanings:
"Alkyl" means a saturated aliphatic hydrocarbon which may be either straight or branched-chained containing from about 1 to about 6 carbon atoms.
"Lower alkyl" means an alkyl group as above, having 1 to about 4 carbon atoms.
"Aralkyl" means an alkyl group substituted by an aryl radical were aryl means a phenyl or phenyl substituted with one or more substituents which may be alkyl, alkoxy, amino, nitro, carboxy, carboalkoxy, cyano, alkyl amino, halo, hydroxy, hydroxyalkyl, mercaptyl, alkyl mercaptyl, carboalkyl or carbamoyl. The preferred aralkyl groups are benzyl or phenethyl.
"Carbamyl" means a group of the formula ##STR4##
"Alkoxy" means an alkyl-oxy group in which "alkyl" is as previously described. Lower alkoxy groups are preferred. Exemplary groups include methoxy, ethoxy, n-propoxy, i-propoxy and n-butoxy.
"Acyl" means an organic radical derived from an organic acid, a carboxylic acid, by the removal of its acid hydroxyl group. Preferred acyl groups are benzoyl and lower alkyl carboxylic acids groups such as acetyl and propionyl.
The chemical structures for the Z groups defined above are presented below. ##STR5##
Certain of the compounds of the present invention may exist in enolic or tautomeric forms, and all of these forms are considered to be included within the scope of this invention.
The compounds of this invention may be useful in the form of the free base, in the form of salts and as a hydrate. All forms are within the scope of the invention. Acid addition salts may be formed and are simply a more convenient form for use; and in practive, use of the salt form inherently amounts to use of the base form. The acids which can be used to prepare the acid addition salts include preferably those which produce, when combined with the free base, pharmaceutically acceptable salts, that is, salts whose anions are non-toxic to the animal organism in pharmaceutical doses of the salts, so that the beneficial cardiotonic properties inherent in the free base are not vitriated by side effects ascribable to the anions. Although pharmaceutically acceptable salts of said basic compound are preferred, all acid addition salts are useful as sources of the free base form even if the particular salt per se is desired only as an intermediate produce as, for example, when the salt is formed only for purposed of purification, and identification, or when it is used as intermediate in preparing a pharmaceutically acceptable salt by ion exchange procedures. Pharmaceutically acceptable salts within the scope of the invention are those derived from the following acids: mineral acids such as hydrochloric acid, sulfuric acid, phosphoric acid and sulfamic acid; and organic acids such as acetic acid, citric acid, lactic acid, tartaric acid, malonic acid, methanesulfonic acid, ethanesulfonic acid, benzenesulfonic acid, p-toluenesulfonic acid, cyclohexylsulfamic acid, quinic acid, and the like. The corresponding acid addition salts comprise the following: hydrochloride, sulfate, phosphate, sulfamate, acetate, citrate, lactate, tartarate, methanesulfonate, ethanesulfonate, benzenesulfonate, p-toluenesulfonate, cyclohexysulfamate and quinate, respectively.
The acid addition salts of the compounds of this invention are prepared either by dissolving the free base in aqueous or aqueous-alcohol solution or other suitable solvents containing the appropriate acid and isolating the salt by evaporating the solution, or by reacting the free base and acid in an organic solvent, in which case the salt separates directly or can be obtained by concentration of the solution.
A preferred class of compounds is described by Formula I: ##STR6## where: X is hydrogen, hydroxy, amino, mono- and di-loweralkylamino, halo, trifluoromethyl, sulfamyl, mono- and di-loweralkylsulfamyl or loweralkylsulfonyl;
Y is loweralkyl, ##STR7## Z is ##STR8## 3-quinuclidine; 4-quinuclidine, 4-(1-azabicyclo[3.3.1]nonane), 3-(9-methylazabicyclo[3.3.1]-nonane), 7-(3-oxo-9-methylazabicyclo[3.3.1]nonane) or 4-[3-methoxy-1-[4-fluorophenoxy]propyl) piperidine];
R 1 , R 2 , R 3 and R 4 are independently hydrogen or loweralkyl;
vicinal R 2 groups may together form a 5- to 7-member carbocyclic ring;
vicinal R 1 groups may form a double bond;
a and b are 1 to 3;
n is 1 to 3;
and pharmaceutically acceptable salts thereof.
More preferred compounds are those of Formula I where:
X is hydrogen or halo;
Y is methyl, ethyl, propyl, i-propyl, butyl, i-butyl, sec-butyl, t-butyl, pentyl, ##STR9## Z is 3-quinuclidine, 4-quinuclidine, 4-(1-azabicyclo[3.3.1]-nonane), 3-(9-methylazabicyclo[3.3.1]-nonane), 7-(3-oxo-9-methylazabicyclo[3.3.1]nonane) or 4-[3-methoxy-1-(3-[4-fluorophenoxy]propyl) piperidine];
R 1 and R 2 are independently hydrogen, methyl or ethyl;
vicinal R 2 groups may together form a 5- and 6-member carbocyclic ring;
vicinal R 1 groups may form a double bond;
a is 1 to 3;
n is 1 or 2;
and pharmaceutically acceptable salts thereof.
The most preferred compounds are those of Formula II: ##STR10## where: X is chloro or bromo;
Z is 3-quinuclidine, 4-quinuclidine or 4-(1-azabicylco[3.3.1]nonane);
R 1 and R 2 are independently hydrogen, methyl or ethyl;
vicinal R 2 groups may together form a 5- or 6-member carbocyclic ring;
vicinal R 1 groups may form a double bond;
and pharmaceutically acceptable salts thereof.
Compounds of this invention may be prepared by the reaction of an amine of the formula H 2 N-Z with a suitably substituted carboxylic acid, acid halide or carboxylic ester of the indene, napthalane, 7(H)-cycloheptabenzene compounds, and dihydro or tetrahydro forms thereof, which correspond to the carboxamide of Formula I.
The carboxylic acid starting compounds and derivatives thereof for the above-mentioned reaction are also novel compounds and comprise part of the present invention. These materials comprise the appropriately substituted indene, indan, napthalene, 1,4-dihydronapthalene, tetralin, 7(H)-cycloheptabenzene, 5,6-dihydro-7(H)-cycloheptabenzene and 5,6,8,9-tetrahydro-7(H)-cycloheptabenzene carboxylic compounds correspondng to the appropriate carboxamide compounds of Formula I.
The carboxylic acid intermediate compounds may be prepared from starting materials such as 4-methoxyindene, 4-methoxyindan, 1-methoxynapthalene, 5-methoxy-1,4-dihydronapthalene, 5-methoxytetralin, 1-methoxy-7(H)-cycloheptabenzene, 1-methoxy-5,6-dihydro-7(H)-cycloheptabenzene or 1-methoxy-5,6,8,9-tetrahydro-7(H)-cycloheptabenzene. These starting materials are commercially available or may be prepared by known methods.
Halogenation of the position para to the ether of the starting material, preferably chlorination with preferred reagents such as N-chloro-succinimide and DMF, affords the methoxy-halo intermediate compound. Further halogenation in the ortho position, preferably bromination with N-bromosuccinimide and DMF, is followed by transformation of the ortho-halo substituent to a carboxy group, preferably by treatment with a strong base such as N-butyllithium and carbon dioxide. The carboxy compound is then reacted with an amine of the formula H 2;l N-Z as defined above to prepare the compounds within the scope of Formula I. The reaction may be conducted at temperatures on the order of 0° C. using a catalytic amount of ethyl chloroformate in chloroform in the presence of triethylamine. The chloroformate adduct is reacted with the amine of the formula H 2 N-Z to obtain the desired carboxamide. The reaction may also be conducted in the presence of a dehydrating catalyst such as a carbodiimide in a solvent at room temperature.
Compounds including various X substituents may be prepared by suitable choice of starting material. Those substituents which require protection may protected and deprotected as necessary or may be converted into the desired substituent from an appropriate precursor group. For example, compounds where X is chloro, bromo or iodo, may be reacted with cuprous cyanide in quinoline at about 150° C. to produce compounds where X is cyano. The cyano group may be converted to the acids, esters or amides.
The halo group may also be converted to the CF 3 group by reaction with trifluoromethyliodide and copper powder at about 150° C. in DMF. The halo group may also be converted to the methylsulfonyl substituent by reaction with cuprous methanesulfinate in quinoline at 150° C.
When X is nitro, selective hydrogenation results in the corresponding amine, which may be mono- or di-alkylated with loweralkyl halides or sulfates. The amino group may also be diazotized to the diazonium fluoride which is then thermally decomposed to the fluorine derivative compound. The amine may also be diazotized and heated in an aqueous medium to form the alcohol or heated in an alcohol to form the alkoxy compound. Chlorosulfonation of the amine group may form the corresponding sulfamyl or mono- and di-alkylsulfamyl groups.
Depending on the chemistry involved in the synthesis, these reactions may be carried out at any appropriate stage of the synthesis. For example, the synthesis of X starting from NO 2 may be done after the closed ring molecule or even after the carboxamide is prepared.
The compounds of this invention may contain at least one asymmetric carbon atom and may have two centers when R 1 =R 2 . As a result, the compounds of Formula I may be obtained either as racemic mixtures or as individual enantiomers. When two asymmetric centers are present the product may exist as a mixture of two diasteromers. The product may be synthesized as a mixture of the isomers and the desired isomer separated by conventional techniques such as chromatography or fractional crystalization from which each diasteromer may be resolved. On the other hand, synthesis may be carried out by known sterospecific processes using the desired form of the inermediate which would result in obtaining the desired specificity.
It is convenient to carry out condensation of the intermediate carboxylic acids mentioned above with the amines of the formula H 2 N-Z using the sterospecific materials. Accordingly, the acid may be resolved into its stereoisomers prior to condensation with resolved amine.
The compounds of this invention may be prepared by the following representative example.
EXAMPLE
The Preparation of (N1-Azabicyclo[2.2.2]oct-3-yl)-8-chloro-5-methoxytetralin-6-carboxamide
Step 1. 5-Methoxytetralin
Tin (II) chloride (0.2 mole) is added to a solution of 5-methoxy-tetralone (0.1 mole) in ethanol-conc. HCl (150 ml, 9:1) at reflux, and the reaction mixture is refluxed for 16 hours, cooled and the alcohol is evaporated. The aqueous residue is diluted with H 2 O, extracted with ether, dried (MgSO 4 ) and evaporated to the desired product.
Step 2. 8-Chloro-5-methoxytetralin
N-Chlorosuccinimide (0.05 mole) is added all at once to the methoxytetralin of step 1 above (0.5 mole) in DMF (150 ml), stirred for 4 hours at 0° C. and poured into ice water. The precipitate is filtered, dried and used as is in the next step.
Step 3. 6-Bromo-8-chloro-5-methoxytetralin
N-Bromosuccinimide (0.028 mole) is added all at once to the chloromethoxytetralin of step 2 above (0.025 mole) in DMF (150 ml) at 0° C., stirred for 4 hours and poured into ice water. The precipitate is filtered, dried and used as is in the next step.
Step 4. 8-Chloro-5-methoxytetralin-6-carboxylic acid N-Butyllithium (0.011 mole, hexane) is added dropwise to the bromochloromethoxytetralin of step 3 above (0.01 mole) in dry THF (100 ml) at -78° C. The reaction mixture is bubbled with CO 2 gas for 5 hours, warmed to 20° C. and poured into 10% aqueous HCl. The precipitate is filtered, dried and used as is in the next step.
Step 5. (N-1-Azabicyclo[2.2.2]oct-3yl)-8-chloro-5-methoxytetralin-6-carboxamide
Ethylchloroformate (4.9 mmoles) is added all at once to the tetralin carboxylic acid of step 4 above (5 mmoles) in chloroform (100 ml) and triethylamine (15 mmoles) at -23° C. and stirred for 1 hour. Aminoquinuclidine dihydrochloride (25 mmoles) and aqueous K 2 CO 3 (25 ml, sat'd) are added to the reaction mixture which is stirred for 1 hour, diluted with H 2 O and separated. The organic layer is washed with H 2 O, dried (MgSO 4 ) and evaporated affording the desired product.
The following compounds are prepared by procedures analogous to those described above.
(N-1-Azabicyclo[2.2.2]oct-3-yl)-7-chloro-4-methoxyindan-5-carboxamide.
(N-1-Azabicyclo[2.2.2]oct-3-yl)-4-chloro-1-methoxy-5,6,8,9-tetrahydro-7(H)-cycloheptabenzene-2-carboxamide.
(1-Azabicyclo[3.3.1]non-3-yl)-8-chloro-5-methoxytetralin-6-carboxamide.
(1-Azabicyclo[3.3.1]non-4-yl)-7-chloro-4-methoxyindan-5-carboxamide.
(1-Azabicyclo[3.3.1]non-4-yl)-4-chloro-1-methoxy-5,6,8,9-tetrahydro-7(H)-cycloheptabenzene-2-carboxamide.
Compounds within the scope of this invention have gastric prokinetic, anti-emetic and lack D 2 receptor binding activity and as such possess therapeutic value in the treatment of upper bowel motility and gastroesophageal reflux disorders. Further, the compounds of this invention may be useful in the treatment of disorders related to impaired gastrointestinal motility such as retarded gastric emptying, dyspepsia, flatulence, oesophageal reflux, peptic ulcer and emesis. Compounds of this invention exhibit 5-HT 3 antagonism and are considered to be useful in the treatment of psychotic disorders such as schizophrenia and anxiety and in the prophylaxis treatment of migraine and cluster headaches. These compounds are selective in that they have little or no dopaminergic antagonist activity.
Various tests in animals can be carried out to show the ability of the compounds of this invention to exhibit pharmacological responses that can be correlated with activity in humans. These tests involve such factors as the effect of the compounds of Formula I on gatric motility, emesis, selective antagonism of 5-HT 3 receptors and their D 2 dopamine receptor binding properties.
One such tst is the "Rat Gastric Emptying: Amberlite Bead Method". This test is carried out as follows:
The study is designed to assess the effects of a test agent on gastric emptying of a solid meal in the rat. The procedure is a modification of those used in L. E. Borella and W. Lippmann (1980) Digestion 20: 26-49.
PROCEDURE
Amberlite beads are placed in a phenol red solution and allowed to soak for several hours. Phenol red serves as an indicator, changing the beads from yellow to purple as their environment becomes more basic. After soaking, the beads are rinsed with 0.1 NaOH to make them purple and then washed with deionized water to wash away the NaOH.
The beads are filtered several times through 1.18 and 1.4 mm sieves to obtain beads with diameters in between these sizes. This is done using large quantities of deionized water. The beads are stored in saline until ready to use.
Male Sprague-Dawley rats are fasted 24 hours prior to the study with water ad libitum. Rats are randomly divided in treatment groups with an N of 6 or 7.
Test agents are prepared in 0.5% methylcellulose and administered to the rats orally in a 10 ml/kg dose volume. Control rats receive 0.5% methylcellulose, 10 ml/kg p.o. One hour after dosing, rats are given 60 Amberlite beads intra-gastrically. The beads are delivered via a 3 inch piece of PE 205 tubing attached to a 16 gauge tubing placed inside the tubing adapter to preent the beads from being pulled back into the syringe. The beads are flushed into each rat's stomach with 1 ml saline.
Rats are sacrificed 30 minutes after receiving the beads and their stomachs are removed. The number of beads remaining in each stomach is counted after rinsing the beads with NaOH.
The number of beads remaining in each stomach is subtracted from 60 to obtain the number of beads emptied. The mean number of beads ± S.E.M. is determined for each treatment group. The percent change from control is calculated as follows: ##EQU1##
Statistical significance may be determined using a t-test for independent samples with a probability of 0.05 or less considered to e significant.
In order to demonstrate the ability of the compounds of this invention as anti-emetic agents the following test for "Cisplatin-Induced Emesis in the Ferret" may be used. This test is a modified version of a paper reported by A. P. Florezyk, J. E. Schurig and W. T. Brodner in Cancer Treatment Reports: Vol. 66, No. 1. January 1982.
Cisplatin had been shown to cause emesis in the dog and cat. Florczyk, et al. have used the ferret to demonstrate the same effects.
PROCEDURE
Male castrated, Fitch ferrets, weighing between 1.0 and 1.5 kg have an in Indwelling catheter placed in the jugular vein. After a 2-3 day recovery period, the experimental procedure is begun.
30 minutes prior to administration of Cisplatin, ferrets are dosed with the compound in 0.9% saine (i.v.) at a dose volume of 2.0 ml/kg.
45 minutes after administration of Cisplatin, ferrets are again dosed with 0.9% saline (i.v.) mixture at a dose volume of 2.0 ml/kg.
Cisplatin is administered (i.v.) 30 minutes after the first dosing with the 0.9% saline. Cisplatin, 10 mg/kg is administered in a dose volume of 2.0 ml/kg.
The time of Cisplatin administration is taken as time zero. Ferrets are observed for the duration of the experiment (4 hours). The elapsed time to the first emetic episode is noted and recorded, as are the total number of periods of emesis.
An emetic (vomiting) episode is characterized by agitated behavior, such as pacing around the cage and rapid to and fro movements. Concurrent with this behavior are several retching movements in a row, followed by a single, large, retch which may or may not expulse gastric contents. Immediately following the single large retch, the ferret relaxes. Single coughs or retches are not counted as vomiting episodes.
D-2 Dopamine Receptor Binding Assay
The D-2 dopamine receptor binding assay has been developed with slight modifications using the method of Ian Cresse, Robert Schneider and Solomon H. Snyder, Europ. J. Pharmacol. 46: 377-381 (1977). Spiroperidol is a butyrophenone neuroleptic whose affinity for dopamine receptors in brain tissue is greater than that of any other known drug. It is a highly specific D-1 dopamine (non-cyclase linked) receptor agent with K 1 values of 0.1-0.5 for D-2 inhibition and 300 nM for D-1 inhibition.
Sodium ions are important regulators of dopamine receptors. The affinity of the D-2 receptor is markedly enhanced by the presence of millimolar concentrations of sodium chloride. The Kd in the absence and presence of 120 mM sodium chloride is 1.2 and o.086 nM respectively. Sodium chloride (120 mM) is included in all assays as a standard condition.
The caudate nucleum (corpous striatum) is used as the receptor source because it contained the highest density of dopamine receptors in the brain and periphery.
PROCEDURE
Male Charles-River rats weighing 250-300 g are decapitated and their brains removed, cooled on ice, and caudate dissected immediately and frozen on dry ice. Tissue can be stored indefinitely at -70° C. For assay caudate is homogenized in 30 ml of tris buffer (pH 7.7 at 25° C.) using the polytron homogenizer. The homogenate is centrifuged at 40,000 g (18,000-19,000 RPM in SS-34 rotor) for 15 minutes. Pellet is resuspended in fresh buffer and centrifuged again. The final pellet is resuspended in 150 volumes of assay buffer.
Specific 3 H-spiroperiodol binding is assayed in a total 2 ml reaction volume consisting of 500 μl of caudate homogenate, 50 mM tris buffer (pH 7.4 at 35° C.), 5 mM MgSO 4 , 2 mM EDTA 2NA, 120 mM NaCl, 0.1% ascorbic acid, 0.4 nM 3 H-spiroperidol and test compound or assay buffer. When catecholamines are included in the assay, 10 μM pargyline should be included in the reaction mixture to inhibit monoamine oxidase. Samples are incubated at 35° C. for 30 minutes followed by addition of 5 ml ice cold 50 mM TRIS (pH 7.7 at 25° C.) and filtration through GF/B glass fiber filters on a Brandel Receptor Binding Filtration apparatus. Filters are washed twice with an additional 5 ml of tris buffer each. Assay groups are performed in triplicate and 1 μM D(+) butaclamol is used to determine nonspecific binding. Filters are placed in vials containing 10 ml of Ecoscint phosphor, shaken for 30 minutes and dpm determined by liquid scintillation spectrophotometry using a quench curve. Proteins are determined by the method of Bradford, M. Anal. Biochem 72, 248(1976) using Bio-Rad's coomassie blue G-250 dye reagent. Bovine gamma Globulin supplied by BIO-RAD is used as the protein standard.
BEZOLD-JARISCH EFFECT IN ANESTHETIZED RATS
Male rats 260-290 g are anesthetized with urethane 1.25 g/kg -1 i.p., and the trachea cannulated. The jugular vein is cannulated for intravenous (i.v.) injection of drugs. Blood pressure is recorded from a cannula in the left carotid artery and connected to a heparin/saline-filled pressure transducer. Continuous heart rate measurements are taken from the blood pressure recordings. The Bezold-Jarisch effect is evoked by rapid, bolus i.v. injections of 5-HT and measurements are made of the fall in heart rate. In each rate, consistent responses are first established with the minimum dose of 5-HT that evokes a clear fall in heart rate. Injections of 5-HT are given every 12 minutes and a dose-response curve for the test compound is established by injecting increasing doses of compound 5 minutes before each injectin of 5-HT. The effect of the compound on the 5-HT-evoked bradycardia is calculated as a percent of the bradycardia evoked by 5-HT before injection of compound.
In separate experiments to measure the duration of 5-HT antagonism caused by the compounds of this invention, a single dose of compound is injected 5 minutes before 5-HT, and the effects of 7 repeated challenges with 5-HT are then monitored. The effects of the compound on the efferent vagal limb of the Bezold-Jarisch reflex are checked by electrically stimulating the peripheral end of a cut vagus nerve. Unipolar electrical stimulation is applied every 5 minutes via a pair of silver electrodes, using 1 ms rectangular pulses in 5 strains with a maximally-effective voltage (20 V at 10 Hz). Pulse frequency may vary from 5-30 Hz and frequency-response curves are constructed before and 10 minutes after i.v. injection of a single dose of compound.
The results of these above tests indicate that the compounds for this invention exhibit a valuable balance between the peripheral and central action of the nervous system and may be useful in the treatment of disorders related to impaired gastro-intestinal motility such as gastric emptying, dyspepsia, flatulence, esophageal reflux and peptic ulcer and in the tretment of disorders of the central nervous system such as psychosis.
The compounds of the present invention can be administered to a mammalian host in a variety of forms adapted to the chosen route of administration, i.e., orally, or parenterally. Parenteral administration in this respect includes administration by the following routes: intravenous, intramuscular, subcutaneous, intraocular, intrasynovial, transepithelially including transdermal, opthalmic, sublingual and buccal; topically including ophthalmic, dermal, ocular, rectal and nasal inhalation via insufflation and aerosol and rectal systemic.
The active compound may be orally administered, for example, with an inert diluent or with an assimilable edible carrier, or it may be enclosed in hard or soft shell gelatin capsules, or it may be compressed into tablets, or it may be incorporated directly with the food of the diet. For oral therapeutic administration, the active compound may be incorporated with excipient and used in the form of ingestible tablets, buccal tablets, troches, capsules, elixirs, suspensions, syrups, wafers, and the like. Such compositions and preparations may, of course, be varied and may conveniently be between about 2 to about 6% of the weight of the unit. The amount of active compound in such therapeutically useful compositions is such that a suitable dosage will be obtained. Preferred compositions or preparations according to the present invention are prepared so that an oral dosage unit form contains between about 50 and 300 mg of active compound.
The tablets, troches, pills, capsules and the like may also contain the following: A binder such as gum tragacanth, acacia, corn starch or gelatin; excipients such as dicalcium phosphate; a disintegrating agent such as corn starch, potato starch, alginic acid and the like; a lubricant such as magnesium stearate; and a sweetening agent such as sucrose, lactose of saccharin may be added or a flavoring agent such as peppermint, oil of wintergreen, or cherry flavoring. When the dosage unit form is a capsule it may contain, in addition to materials of the above type, a liquid carrier. Various other materials may be present as coatings or to otherwise modify thephysical form of the dosage unit. For instance, tablets, pills, or capsules may be coated with shellac, sugar or both. A syrup or elixir may contain the active compound sucrose as a sweetening agent, methyl and propylparabens as preservatives, a dye and flavoring such as cherry or orange flavor. Of course, any material used in preparing any dosage unit form should be pharmaceutically pure and substantially non-toxic in the amounts employed. In addition, the active compound may be incorporated into sustained-release preparations and formulations.
The active compound may also be administered parenterally or intraperiotoneally. Solutions of the active compound as a free base or pharmacologically acceptable salt can be prepared in water suitably mixed with a surfactant such as hydroxypropylcellulose. Dispersion can also be prepared in glycerol, liquid polyethylene glycols, and mixtures thereof and in oils. Under ordinary conditions of storage and use, these preparations contain a preservative to prevent the growth of microorganisms.
The pharmaceutical forms suitable for injectable use include sterile aqueous solutions or dispersions and sterile powders for the extemporaneous preparation of sterile injectable solutions or dispersions. In all cases the form must be sterile and must be fluid to the extent that easy syringability exists. It may be stable under the conditions of manufacture and storge and must be preserved against the contaminating action of microorganisms such as bacteria and fungi. The carrier can be a solvent or dispersion medium containing, for example, water, ethanol, polyol (for example, glycerol, propylene glycol, and liquid polyethylene glycol, and the like), suitable mixtures thereof, and vegetable oils. The proper fluidity can be maintained, for example, by the use of a coating such as lecithin, by the maintenance of the required particle size in the case of dispersion and by the use of surfactants. The prevention of the action of microorganisms can be brought about by various antibacterial and antifungal agents, for example, parabens, chlorobutanol, phenol, sorbic acid, thimersal, and the like. In many cases, it will be preferable to include isotonic agents, for example, sugars or sodium chloride. Prolonged absorption of the injectable compositions involves the incorporation of an agent delaying absorption, for xample, aluminum monostearate and gelatin.
Sterile injectable solutions are prepared by incorporating the active compound in the require amount in the appropriate solvent with various of the other ingredients enumerated above, as required, followed by filtered sterilization. Generally, dispersions are prepared by incorporating the various sterilized active ingredients into a sterile vehicle which contains the basic dispersion medium and the required other ingredients from those enumerated above. In the case of sterile powders for the preparation of sterile injectable solutions, the preferred methods of preparations are vacuum drying and the freeze drying technique which yield a powder of the active ingredient plus any additional desired ingredient from previously sterile-filtered solution thereof.
The therapeutic compounds of this invention may be administered alone to a mammal or in combination with pharmaceutically acceptable carriers, as noted above, the proportion of which is determined by the solutibility and chemical nature of the compound, chosen route of administration and standard pharmaceutical practice.
The physician will determine the dosage of the present therapeutic agents which will be most suitable for prophylaxis or treatment and will vary with the form of administration and the particular compound chosen, and also, it will vary with the particular patient under treatment. He will generally wish to initiate treatment with small dosages by small increments until the optimum effect under the circumstances is reached. The therapeutic dosage will generally be from 0.1 to 20 mg or from about 0.01 mg to about 5 mg/kg of body weight per day and higher although it may be administered in several different dosage units from once to several times a day. Higher dosages are required for oral administration. | Certain specific substituted benzobicyclic carboxamides and their valuable use as 5-HT3 antagonists having CNS and gastric prokenetic activity void of any significant D 2 receptor binding activity are disclosed. | 2 |
RELATED APPLICATION
This application is a continuation-in-part of my co-pending application Ser. No. 046,461, filed May 4, 1987 now abandoned.
BACKGROUND AND SUMMARY OF INVENTION
This invention relates to a pipe seal assembly for use in on-site waste disposal systems, such as in a septic system having a poured concrete septic tank, drop box or distribution box.
These tanks and boxes are box-shape structures constructed of concrete and have plural openings for the receipt of outlet and inlet pipes. Depending upon the particular arrangement, a number of pipes may be employed at one or more levels and the maximum number of openings are usually provided in the box. In certain prior constructions, the openings were simply holes formed in the box's side walls. More recently, these openings may be initially closed by seal assemblies and those openings for which pipes are intended have a removable portion of the seal assembly removed. The remaining part of the seal assembly is adapted to provide a water-tight seal for the inserted pipe.
A problem has arisen with respect to seal assemblies where flowing concrete has interfered with the seal to be developed with the pipe. Additionally, another disadvantage of known seals which mount on form mandrels is that they must be manually held in place while the form is open before casting, until such time as the form is closed; otherwise the seals simply fall off the mandrels.
The problems are avoided by the instant invention. More particularly, the instant invention provides for a releasably retained knock-out plug positioned adjacent the end of the seal assembly and, when the seal assembly is cast in place in the concrete box, the plug is located near the interior wall of the box. A specially configured mandrel supported on the form wall operates to releasably hold the seal and plug in place during casting of the box. The mandrel can include gripper structure for frictionally holding the seal in place, or can include undercut structure for gripping the seal. Additionally, the present seals' cylindrical body portion can be so dimensioned that the back of one seal can be placed over the front of another seal, such that a connected series of such seals mounted on only one mandrel can be used to seal a pipe through a thick poured concrete basement wall, for example.
Other objects and advantages of the invention may be seen in the details of the ensuing specification.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in conjunction with the accompanying drawings, in which
FIG. 1 is an exploded perspective view of the parts of the invented seal assembly;
FIG. 1-A is a side elevation view of the various parts of FIG. 1 in assembled form;
FIG. 2 is a diametral sectional view of the wall member portion of the seal assembly;
FIG. 3 is a diametral sectional view of the mandrel portion of the seal assembly;
FIG. 4 is an end elevational view of the mandrel of FIG. 3;
FIG. 5 is a diametral sectional view of the seal assembly with the parts in assembled condition;
FIG. 6 is an exploded sectional view of the parts seen in FIG. 1, and with certain form portions shown in phantom;
FIG. 7 is a fragmentary perspective view of the present seal assembly installed in a concrete box and with the plug shown in the stage of being removed;
FIG. 8 is a sectional view of the present seal's components, similar to FIG. 6, but in assembled fashion and with additional form portions, ready to be cast in place;
FIG. 9 is a fragmentary sectional view of the seal assembly shown cast in place prior to removal of the knock-out plug;
FIG. 10 is a fragmentary sectional view of the seal assembly with the mandrel and plug removed and with a pipe installed therein;
FIG. 11 is similar to FIG. 8, but depicting an alternate embodiment of the mandrel and wall member of the present seal assembly;
FIG. 12 is a sectional view of a connected series of the present seal assemblies, for use in sealing pipes through thick concrete wall sections; and
FIG. 13 is a sectional view of a connected series of the present seal assemblies, similar to FIG. 12, but with certain elements in reversed relationship.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the illustration given, wherein like reference numerals indicate corresponding elements, and with reference first to FIGS. 1 and 1-A, the numeral 9 designates generally the seal assembly of the instant invention. FIG. 1 also shows the parts in exploded perspective view with the numeral 10 generally designating the seal member and with numeral 11 designating a cylindrical seal wall member therefor. Mounted within the seal member 10 is a mandrel 12 which carries a mounting bolt 13, such as a carriage bolt with a square underhead, for example. A spacer member 14 having strengthening ribs 14-A may be optionally provided depending upon the thickness of the poured box wall in which the seal assembly 9 is to be cast. As the last discrete element of the seal assembly 9, a knock-out plug 15 is provided.
The basic installation is known. The seal assembly 9, in its tightly assembled condition shown in the lower half of FIG. 1, is attached by bolt 13 to the hinged jacket door (illustrated schematically as at 16 in the right hand portion of FIGS. 6 and 8) of a septic box concrete form (not shown in full) and with the jacket door 16 closed to its form-providing position. In that condition (see FIG. 8), the form is now ready for concrete to be poured which surrounds the seal member 10 in the fashion generally depicted in FIGS. 9 and 10 wherein the concrete is designated 17.
Referring now to FIG. 2, the seal member 10 is seen in greater detail. The seal member 10 has a first end 18 which is adapted to be positioned toward the exterior wall 17-A of the box as can be appreciated from FIGS. 7-10. The seal member 10 has a second end 19 which is adapted to be positioned adjacent the interior wall 17-B of the box formed by the concrete wall 17.
The seal member 10 has a main cylindrical wall member 11 with an outer cylindrical wall 11a and an inner cylindrical wall 11b. Projecting radially outward from the outer cylindrical wall 11a is an integral anchor flange 20--see FIG. 2--which is intended to become embedded in the concrete 17 and serve as an anchor as is best illustrated in FIGS. 9 and 10. The flange 20 at its periphery is equipped with a generally axially extending flange 21 which assists in developing the anchoring. The outer wall 11a may be provided with, if desired, an additional anchoring lip 27 (see FIG. 10).
The circumferentially extending inner wall 11b of seal member 10 at the first end 18 is equipped with an integral, relatively flexible, frusto-conical shaped flange member 22 which is angled toward the second end 19 but terminates short thereof. As can be best appreciated from FIG. 5, the flange member or reverse wiper blade 22 serves, in part, as a releasable keeper or retainer for a beveled retainer flange or undercut portion 23 provided on the interiorily facing end of the mandrel 12. The inner free end 22-A of flange 22 provides a circular opening along the axis of the seal member 10 into which the mandrel 12 and the undercut 23 is releasably received. The side wall 12A of mandrel 12 is preferably sloped generally inwardly (towards the undercut 23) at the same angle as wiper blade 22 of seal member 10. In addition the mandrel 12 has a generally spider webbed internal configuration (see webs indicated by reference letter "W" in FIG. 4) providing an axial opening as at 24 for the receipt of the retainer bolt 13--see FIGS. 4 and 6. The opening 24 includes an enlarged circular recess 24-A and a square-shaped recess 24-B which respectively receive the round head and square underhead of the retainer bolt 13. The bolt 13 also extends through the spacer element 14 and outer hinged form wall 16, which are also seen in FIG. 6, and receives a washer 13-A and a nut 13-B.
The circumferentially extending inner wall 11b at the second end thereof--as at 19--is equipped with a radially inwardly extending flange 25 which adjoins a recess 26 formed in wall 11b (see FIG. 2). Together the flange 25 and recess 26 cooperate to releasably retain the knock-out plug 15 in the fashion depicted in FIG. 5, i.e., in the space between the interior end of the mandrel 12 and the flange 25. Further, the outer peripheral edge (referenced by letter "T" in FIG. 6) of planar plug 15 can be tapered inwardly (as shown in FIG. 6), whereby the outer locking edge or corner (referred by letter "L" in FIG. 6) operates to form a better locking grip against flange 25 and recess 26. Moreover, such a tapered edge T on plug 15 also makes it easier to insert plug 15 into end 19 of seal member 10.
In certain instances the inner or second end 19 of seal member 10 preferably bears directly against the inner core wall 16A of the box form (see FIG. 8), such as desirably occurs when casting a plurality of seal assemblies 9 in the walls of a septic system distribution box (not shown), for example. In those instances there is no concrete flashing formed in front of the plug 15 due to the tight engagement of seal end 19 against form core wall 16-A. However, in other instances the inner end 19 of seal member 10 is purposely spaced somewhat from the form core wall 16-A, such as occurs when casting a plurality of seal assemblies 9 in the walls of a septic tank (see FIG. 9). In those situations a thin concrete flashing noted by reference letter "F" is formed in front of the knock-out plug 15.
In operation, the seal assembly 9, such as generally seen in FIGS. 6 and 8, is mounted within the box form by bolting the tightly assembled seal assembly 9 to the hinged form wall 16 with washer 13-A and nut 13-B. This mounting can be done at any desired height level on the box form wall 16. If required to be used in casting a particular type box, such as with septic tanks, for example, the spacer 14 can be of any desired thickness, such as for casting the seal assembly 9 in 2", 21/2", 3", or even thicker walls. The spacer 14 can be deleted when thinner-walled boxes, such as 11/2" or 13/4" thick distribution boxes or drop boxes, for example, are being cast with seal assembly 9. In any event, when the concrete 17 has been poured, the mandrel 12 and bolt 13 and any spacer 14 are removed, i.e., stripped out of seal member 10 when the jacket door 16 is hinged open. That is, the undercut 23 on mandrel 12 is released from the grip of the inner free end 22-A of flexible wiper blade 22.
However, the seal assembly 9 still provides the option of a pipe seal or a closure seal because of the mounting of plug 15 within the recess 26 of seal member 10. If a particular opening (which is developed in the concrete box wall 17 by using, i.e., casting in place, the seal assembly 9) is not to be used for a pipe, the plug 15 is left in place. In that instance, especially where a concrete flashing F is present, the flashing F and plug 15 cooperate to seal off the opening and maintain the box wall's integrity at that point. In actual practice, it has been found that the flashing F may force the plug 15 axially along seal wall 11b until plug 15 sealably bears against free end 22-A of wiper blade 22.
Even in those cases where the flashing F is not present, the plug member 15 becomes tightly sealed against the inner cylindrical wall 11b due to the shrinking forces of concrete wall 17 about outer cylindrical seal wall 11a adjacent the recess 26.
On the other hand, if a pipe is to be installed in a particular opening (as indicated in FIG. 9), the plug 15 is removed as illustrated in FIG. 7. This can be done by using a hammer (not shown) to knock out the plug 15 and slug of concrete flashing F, if any. The pipe P is thereafter inserted in the seal member 10. That is, as illustrated in FIG. 9, the pipe P slides into the axial opening developed by the removal of the mandrel 12 and is tightly sealed by the flexible wiper blade 22.
Not only does the plug 15 provide a permanent seal in the event no pipe is to be installed but also serves to preclude the entry of fluid concrete within the seal member 10 during pouring of the box wall. Without the presence of the plug 15, concrete could enter in the space S (see FIG. 5) between the circumferential inner wall 11B and the wiper blade 22 and thereby prevent the necessary flexure, i.e., slightly stretched expansion, of the free end of blade 22 into its pipe-sealing configuration as shown in FIG. 9. Thus, it will be understood that because of the presence of separate plug 15, the second end 19 of the seal member 10 need not be forced against form core wall 16-A to successfully function in casting the seal assembly 9 in place, although such positioning can be done if desired in a given box casting operation. That is, the seal assembly of the present invention need only be mounted to the outer hinged form wall 16, rather than be accurately positioned between both form walls 16-A and 16 as was required with prior art designs.
Corrosion-resistant, durable and inert plastic-type materials are preferably used to form, such as by injection molding techniques, the various components of the seal assembly 9. In the preferred embodiment, the seal member 10 is made of linear low density polyethylene; it also could be formed of low density polyethylene. The knock-out plug 15 is formed of high density polyethylene. The mandrel 12, primary because of the need for durability due to repetitive use in casting concrete boxes with seals made according to the present invention, is made of polypropylene. Alternatively, Nylon or so-called A.B.S. plastic materials could be used for the plug 15. The spacer 14 is also formed of polypropylene.
It will be understood that the opening formed by free end 22A of flexible wiper blade 22 is so sized as to sealably receive substantially all of the customary 4" drain pipes used in on-site waste disposal systems. Thus, the opening in seal member 10 of the preferred embodiment of the present invention is 3.850 inches in diameter; due to the seal's flexibility and stretchability it will fit so-called thin wall 4" P.V.C. (polyvinyl chloride) pipe, typified by pipe known as A.S.T.M. 27-29. Also, seal member 10 will accommodate so-called medium wall thickness 4" pipe, typified by A.S.T M. 30-34 pipe, as well as heavy walled 4" pipe, such as Schedule 40 P.V.C. and 4" cast iron pipes.
If desired, a plurality of inwardly radially-extending, axially aligned gusset members 30 (shown in phantom in FIG. 9) can be formed on inner cylindrical wall 11b. The purpose for such gussets 30 is to provide additional strength and support to the wiper blade 22 when a pipe P inserted therein is forced down against the lower half of the wiper blade 22, such as when the backfill around the concrete box permits or forcibly causes the pipe P to settle downwardly. Thus, the gussets help prevent any undesirable gap to occur between the blade 22 and pipe P. Normally, these gussets (if additionally provided on the seal member 10, as desired) do not contact the wiper blade 22.
Another preferred embodiment of the present invention is shown in FIG. 11, which is similar to FIG. 8, and wherein like reference numerals indicate corresponding elements, except for modified elements for which the reference numerals bear a prime mark. In this additional preferred embodiment, wherein the modified seal assembly is generally denoted by reference numeral 9', the seal member 10' has a cylindrical seal wall member 11', a flexible, reverse-angled wiper blade 22, and an anchor flange 20 with flange 21. The inner cylindrical wall, designated by reference number 11b', is modified in that it is formed with a smooth-wall completely out to the second end 19 of seal member 10'. Thus, modified wall 11b' does not include any flange 25 or recess 26, such as present on inner wall 11b of seal member 10 (see FIG. 2).
A modified mandrel 12' is mounted within the seal member 10' and, although otherwise similar to mandrel 12, terminates in an interiorly-facing end 31 which is formed in an axially extending, cylindrical, smooth-walled fashion so as not to include any undercut portion 23 (like on mandrel 12, see FIG. 3). Importantly, the cylindrical end 31 of modified mandrel 12' is purposely dimensioned so as to be slightly larger in diameter than the inner free end 22-A of wiper blade 22. This is done so that a tight frictional securement of blade 22 on mandrel end 31 will occur when modified seal member 10' is mounted on the modified mandrel 12' during the casting process. That is, the wiper blade free end 22-A is slightly stretched over mandrel end 31 when assembled thereon, so that a tight frictional engagement occurs, which thus assures that the modified seal 10' will not become dislodged off modified mandrel 12' during the concrete casting process, yet can be readily stripped therefrom after the casting process has been completed. It is additionally believed that a suction effect is created between the wall of the mandrel 12' and the wiper blade 22 which additionally assists in maintaining engagement between the same during casting.
Further, because of the fact that the poured concrete 17 presses against wall 11a, as well as against the plug 15 during the casting process, and thus forces plug 15 along modified inner seal wall 11b' against free end 22-A of wiper blade 22, it has been found that no inwardly-directed flange 25 or recess 26 is required to adequately secure plug 15 to the cylindrical wall 11' during casting.
In all other respects the modified seal assembly 9' utilizes the same components and operates in the same fashion as seal assembly 9.
Although described with reference to a pipe seal for an on-site waste disposal system, it will be understood that the seal assemblies 9 and 9' of the present invention readily lend themselves to sealing pipes and similar conduits in other concrete boxes, such as in utility pull boxes, or in residential basement walls where a sewer outlet line projects through the basement wall. For example, as seen in FIG. 12, to seal a sewer line 32 through a thick basement wall 33, a series of seal members 10 could be cast in place in such a wall in abutting front-to-back relationship. That is, the first seal 10 would be snap fitted, i.e., releasably retained, to the mandrel 12 (not shown in FIG. 12, but see FIG. 8), with a second seal member 10 having its end 18 inserted over (or inserted into, as desired) the opening of the first seal member 10 created by that seal member's other end 19. Thus, in continuous fashion, a number of seal members 10 could be so physically attached together until the innermost seal member 10 would be closed-off as described above with a seal plug 15 (not shown in FIG. 12, but see FIG. 5) or could be jammed against the outer form wall for the thick concrete wall 33. Thus, once cast in place, such a plurality of seal members 10 would provide a plurality of wiper blades 22, all in an aligned orientation, to sealably receive and support a sewer line 32 through a thick concrete basement wall 33.
Thus, while in the foregoing specification a detailed description of preferred embodiments of the present invention have been set down for the purpose of illustration, many variations in the details herein given may be made by those skilled in the art without departing from the spirit and scope of the invention. | A pipe seal assembly for a poured concrete tank or box in an on-site waste disposal system including a seal member having an inclined inner wiper flange which releasably retains a mandrel, and plug means also releasably mounted within the seal member to prevent ingress of liquid concrete during box formation. A spacer member is provided for those instances where the seal member is to be installed in the wall of a relatively thick-walled concrete box. Alternate means for releasably retaining the seal member to the mandrel are disclosed. Additionally, a series of such seal assemblies is disclosed for use in sealably attaching a pipe through a thick poured concrete wall, such as a basement wall. | 4 |
This is a divisional of application(s) Ser. No. 08/205,009, filed on Mar. 2, 1994, now U.S. Pat. No. 5,380,888; which is a divisional of application Ser. No. 07/928,589, filed on Aug. 13, 1992, now U.S. Pat. No. 5,328,902.
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
The invention relates to novel [4S-(4alpha,12aalpha)]-4-(dimethylamino)-7-(substituted)-9-[(substituted glycyl)amido]-1,4,4a,5,5a,6,11,12a-octahydro-3,10,12,12a-tetrahydroxy-1,11-dioxo-2-naphthacenecarboxamides herein after called 7-(substituted)-9-[(substituted glycyl)amido]-6-demethyl-6-deoxytetracyclines, which exhibit antibiotic activity againsts a wide spectrum of organisms including organisms which are resistant to tetracyclines and are useful as antibiotic agents.
The invention also relates to novel 9-[(haloacyl)amido]-7-(substituted)-6-demethyl-6-deoxytetracycline intermediates useful for making the novel compounds of the present invention and to novel methods for producing the novel compounds and intermediate compounds.
SUMMARY OF THE INVENTION
This invention is concerned with novel 7-(substituted)-9-[(substituted glycyl)amido]-6-demethyl-6-deoxytetracyclines, represented by formula I and II, which have antibacterial activity; with methods of treating infectious diseases in warm blooded animals employing these new compounds; with pharmaceutical preparations containing these compounds; with novel intermediates compounds and processes for the production of these compounds. More particularly, this invention is concerned with compounds of formula I and II which have enhanced antibacterial activity against tetracycline resistant strains as well as a high level of activity against strains which are normally susceptible to tetracyclines. ##STR2##
In formula I and II,
R is a halogen selected from bromine, chlorine, fluorine and iodine; or R=--NR 1 R 2 and when R=--NR 1 R 2 and R 1 =hydrogen,
R 2 =methyl, ethyl, n-propyl, 1-methylethyl, n-butyl, 1-methylpropyl, 2-methylpropyl or 1,1-dimethylethyl; and when R 1 =methyl or ethyl,
R 2 =methyl, ethyl, n-propyl, 1-methylethyl, n-butyl, 1-methylpropyl or 2-methylpropyl;
and when R 1 =n-propyl,
R 2 =n-propyl, 1-methylethyl, n-butyl, 1-methylpropyl or 2-methylpropyl;
and when R 1 =1-methylethyl,
R 2 =n-butyl, 1-methylpropyl or 2-methylpropyl; and when R 1 =n-butyl,
R 2 =n-butyl, 1-methylpropyl or 2-methylpropyl;
and when R 1 =1-methylpropyl,
R 2 =2-methylpropyl;
R 3 is selected from hydrogen; straight or branched (C 4 -C 8 )alkyl group selected from butyl, isobutyl, pentyl, hexyl, heptyl and octyl;
α-mercapto(C 1 -C 4 )alkyl group selected from mercaptomethyl, α-mercaptoethyl, α-mercapto-1-methylethyl and α-mercaptopropyl;
α-hydroxy(C 1 -C 4 )alkyl group selected from hydroxymethyl, α-hydroxyethyl, α-hydroxy-1-methylethyl and α-hydroxypropyl; carboxyl(C 1 -C 8 )alkyl group;
(C 6 -C 10 )aryl group selected from phenyl, α-naphthyl and β-naphthyl; substituted(C 6 -C 10 )aryl group (substitution selected from hydroxy, halogen, (C 1 -C 4 )alkoxy, trihalo(C 1 -C 3 )alkyl, nitro, amino, cyano, (C 1 -C 4 )alkoxycarbonyl, (C 1 -C 3 )alkylamino and carboxy);
(C 7 -C 9 )aralkyl group selected from benzyl, 1-phenylethyl, 2-phenylethyl and phenylpropyl;
substituted (C 7 -C 9 )aralkyl group [substitution selected from halo, (C 1 -C 4 )alkyl, nitro, hydroxy, amino, mono- or all-substituted (C 1 -C 4 )alkylamino, (C 1 -C 4 )alkoxy, (C 1 -C 4 )alkylsulfonyl, cyano and carboxy];
R 4 is selected from hydrogen and (C 1 -C 6 )alkyl selected from methyl, ethyl, propyl, isopropyl, butyl, isobutyl, pentyl and hexyl;
when R 3 does not equal R 4 the stereochemistry of the asymmetric carbon (i.e. the carbon bearing the substituent W) maybe be either the racemate (DL) or the individual enantiomers (L or D);
W is selected from hydroxylamino; (C 7 -C 12 ) straight or branched alkyl monosubstituted amino group substitution selected from heptyl, octyl, nonyl, decyl, undecyl, dodecyl and the diastereomers and enantiomers of said branched alkyl monosubstituted amino group;
(C 1 -C 4 ) straight or branched fluoroalkylamino group selected from trifluoromethyl, 2,2,2-trifluoroethyl, 3,3,3-trifluoropropyl, 3,3,3,2,2-pentafluoropropyl, 2,2-difluoropropyl, 4,4,4-trifluorobutyl and 3,3-difluorobutyl; (C 3 -C 8 )cycloalkyl monosubstituted amino group substitution selected from cyclopropyl, trans-1,2-dimethylcyclopropyl, cis-1,2-dimethylcyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, bicyclo[2.2.1]hept-2-yl, bicyclo[2.2.2]oct-2-yl and the diastereomers and enantiomers of said (C 3 -C 8 )cycloalkyl monosubstituted amino group; [(C 4 -C 10 )cycloalkyl]alkyl monosubstituted amino group substitution selected from (cyclopropyl)methyl, (cyclopropyl)ethyl, (cyclobutyl)methyl, (trans-2-methylcyclopropyl)methyl, and (cis-2-methylcyclobutyl)methyl; (C 3 -C 10 )alkenyl and alkynyl monosubstituted amino group substitution selected from allyl, 3-butenyl, 2-butenyl (cis or trans), 2-pentenyl, propynyl, 4-octenyl, 2,3-dimethyl-2-butenyl, 3-methyl-2-butenyl, 2-cyclopentenyl and 2-cyclohexenyl; (C 6 -C 10 )aryl monosubstituted amino group substitution selected from phenyl and naphthyl; (C 7 -C 10 )aralkylamino group substitution selected from benzyl, 2-phenylethyl, 1-phenylethyl, 2-(naphthyl)methyl, 1-(naphthyl)methyl and phenylpropyl; substituted (C 6 -C 10 )aryl monosubstituted amino group [substitution selected from (C 1 -C 5 )acyl, (C 1 -C 5 )acylamino, (C 1 -C 4 )alkyl, mono or disubstituted (C 1 -C 8 )alkylamino, (C 1 -C 4 )alkoxy, (C 1 -C 4 )alkoxycarbonyl, (C 1 -C 4 )alkylsulfonyl, amino, carboxy, cyano, halogen, hydroxy, nitro and trihalo(C 1 -C 3 )alkyl]; straight or branched symmetrical disubstituted (C 6 -C 14 )alkylamino group substitution selected from dibutyl, diisobutyl, di-sec-butyl, dipentyl, diisopentyl, di-sec-pentyl, dihexyl, diisohexyl and di-sec-hexyl; symmetrical disubstituted (C 6 -C 14 )cycloalkylamino group substitution selected from dicyclopropyl, dicyclobutyl, dicyclopentyl, di(dicyclopropyl)methyl, dicyclohexyl and dicycloheptyl; straight or branched unsymmetrical disubstituted (C 3 -C 14 )alkylamino group wherein the total number of carbons in the substitution is more than 14; unsymmetrical disubstituted (C 4 -C 14 )cycloalkylamino group wherein the total number of carbons in the substitution is no more than 14; (C 2 -C 8 )azacycloalkyl and substituted (C 2 -C 8 )azacycloalkyl group substitution selected from 4-methylpiperidine, 4-hydroxypiperidine, 4-(hydroxymethyl)piperidine, 4-(aminomethyl)piperidine, cis-3,4-dimethylpyrrolidinyl, trans-3,4-dimethylpyrrolidinyl, 2-azabicyclo[2.1.1]hex-2-yl, 5-azabicyclo[2.1.1]hex-5-yl, 2-azabicyclo[2.2.1]hept-2-yl, 7-azabicyclo[2.2.1]hept-7-yl, 2-azabicyclo[2.2.2]oct-2-yl and the diastereomers and enantiomers of said (C 2 -C 8 )azacycloalkyl and substituted (C 2 -C 8 )azacycloalkyl group; substituted 1-azaoxacycloalkyl group substitution selected from 2-(C 1 -C 3 )alkylmorpholinyl, 3-(C 1 -C 3 )alkylisoxazolidinyl, tetrahydrooxazinyl and 3,4-dihydrooxazinyl; [1,n]-diazacycloalkyl and substituted [1,n]-diazacycloalkyl group selected from piperazinyl, 2-(C 1 -C 3 )alkylpiperazinyl, 4-(C 1 -C 3 )alkylpiperazinyl, 2,4-dimethylpiperazinyl, 4-(C 1 -C 4 )alkoxypiperazinyl, 4-(C 6 -C 10 )aryloxypiperazinyl, 4-hydroxypiperazinyl, 2,5-diazabicyclo[2.2.1]hept-2-yl, 2,5-diaza-5-methylbicyclo[2.2.1]hept-2-yl, 2,3-diaza-3-methylbicyclo[2.2.2]oct-2-yl, 2,5-diaza-5,7-dimethylbicyclo[2.2.2]oct-2-yl and the diastereomers or enantiomers of said [1,n]-diazacycloalkyl and substituted [1,n]-diazacycloalkyl group;
1-azathiacycloalkyl and substituted 1-azathiacycloalkyl group selected from thiamorpholinyl, 2-(C 1 -C 3 )alkylthiomorpholinyl and 3-(C 3 -C 6 )cycloalkylthiomorpholinyl; N-azolyl and substituted N-azolyl group selected from 1-imidazolyl, 2-(C 1 -C 3 )alkyl-1-imidazolyl, 3-(C 1 -C 3 )alkyl-1-imidazolyl, 1-pyrrolyl, 2-(C 1 -C 3 )alkyl-1-pyrrolyl, 3-(C 1 -C 3 )alkyl-1-pyrrolyl, 1-pyrazolyl, 3-(C 1 -C 3 )alkyl-1-pyrazolyl, indolyl, 1-(1,2,3-triazolyl), 4-(C 1 -C 3 )alkyl-1-(1,2,3-triazolyl), 5-(C 1 -C 3 )alkyl-1-(1,2,3-triazolyl), 4-(1,2,4-triazolyl, 1-tetrazolyl, 2-tetrazolyl and benzimidazolyl; (heterocycle)amino group said heterocycle selected from 2- or 3-furanyl, 2- or 3-thienyl, 2-, 3- or 4-pyridyl, 2- or 5-pyridazinyl, 2-pyrazinyl, 2-(imidazolyl), (benzimidazolyl), and (benzothiazolyl) and substituted (heterocycle)amino group (substitution selected from straight or branched (C 1 -C 6 )alkyl); (heterocycle)methylamino group selected from 2- or 3-furylmethylamino, 2- or 3-thienylmethylamino, 2-, 3- or 4-pyridylmethylamino, 2- or 5-pyridazinylmethylamino, 2-pyrazinylmethylamino, 2-(imidazolyl)methylamino, (benzimidazolyl)methylamino, and (benzothiazolyl)methylamino and substituted (heterocycle)methylamino group (substitution selected from straight or branched (C 1 -C 6 )alkyl); carboxy(C 2 -C 4 )alkylamino group selected from aminoacetic acid, α-aminopropionic acid, β-aminopropionic acid, α-butyric acid, β-aminobutyric acid and the enantiomers of said carboxy (C 2 -C 4 )alkylamino group; 1,1-disubstituted hydrazino group selected from 1,1,-dimethylhydrazino, N-aminopiperidinyl, 1,1-diethylhydrazino, and N-aminopyrroli-dinyl; (C 1 -C 4 )alkoxyamino group substitution selected from methoxy, ethoxy, n-propoxy, 1-methylethoxy, n-butoxy, 2-methylpropoxy and 1,1-dimethylethoxy; (C 3 -C 8 )cycloalkoxyamino group selected from cyclopropoxy, trans-1,2-dimethylcyclopropoxy, cis-1,2-dimethylcyclopropoxy, cyclobutoxy, cyclopentoxy, cyclohexoxy, cycloheptoxy, cyclooctoxy, bicyclo[2.2.1]hept-2-yloxy, bicyclo[2.2.2]oct-2-yloxy and the diastereomers and enantiomers of said (C 3 -C 8 )cycloalkoxyamino group;
(C 6 -C 10 )aryloxyamino group selected from phenoxyamino, 1-naphthyloxyamino and 2-naphthyloxyamino;
(C 7 -C 11 )arylalkoxyamino group substitution selected from benzyloxy, 2-phenylethoxy, 1-phenylethoxy, 2-(naphthyl)methoxy, 1-(naphthyl)methoxy and phenylpropoxy;
[β or γ-(C 1 -C 3 )acylamido]alkylamino group substitution selected from 2-(formamido)ethyl, 2-(acetamido)ethyl, 2-(propionylamido)ethyl, 2-(acetamido)propyl, 2-(formamido)propyl and the enantiomers of said [β or γ-(C 1 -C 3 )acylamido]alkylamino group; β or γ-(C 1 -C 3 )alkoxyalkylamino group substitution selected from 2-methoxyethyl, 2-ethoxyethyl, 2,2-diethoxyethyl, 2-methoxypropyl, 3-methoxypropyl, 3-ethoxypropyl, 3,3-diethoxypropyl and the enantiomers of said β or γ-(C 1 -C 3 )alkoxyalkylamino group; β, γ, δ (C 2 -C 4 ) hydroxyalkylamino group substitution selected from 2-hydroxyethyl, 2-hydroxypropyl, 3-hydroxypropyl and 4-hydroxybutyl;
or R 3 and W taken together are selected from --(CH 2 ) n (R 5 )N--, n=3-4, and --CH 2 CH(OH)CH 2 (R 5 )N-- wherein R 5 is selected from hydrogen and (C 1 -C 3 ) acyl, the acyl selected from formyl, acetyl, propionyl and (C 2 -C 3 )haloacyl selected from chloroacetyl, bromoacetyl, trifluoroacetyl, 3,3,3-trifluoropropionyl and 2,3,3-trifluoropropionyl;
R 6 is selected from hydrogen; straight or branched (C 1 -C 3 )alkyl group selected from methyl, ethyl, n-propyl or 1-methylethyl; (C 6 -C 10 )aryl group selected from phenyl, α-naphthyl or β-naphthyl; (C 7 -C 9 )aralkyl group such as benzyl, 1-phenylethyl, 2-phenylethyl or phenylpropyl; a heterocycle group selected from a five membered aromatic or saturated ring with one N, O, S or Se heteroatom optionally having a benzo or pyrido ring fused thereto: ##STR3## Z=N, O, S or Se such as pyrrolyl, N-methylindolyl, indolyl, 2-pyrrolidinyl, 3-pyrrolidinyl, 2-pyrrolinyl, tetrahydrofuranyl, furanyl, benzofuranyl, tetrahydrothienyl, thienyl, benzothienyl or selenazolyl, or a five membered aromatic ring with two N, O, S or Se heteroatoms optionally having a benzo or pyrido ring fused thereto: ##STR4## Z or Z 1 =N, O, S or Se such as imidazolyl, pyrazolyl, benzimidazolyl, oxazolyl, benzoxazolyl, indazolyl, thiazolyl, benzothiazolyl, 3-alkyl-3H-imidazo[4,5-b]pyridyl or pyridylimidazolyl, or a five membered saturated ring with one or two N, O, S or Se heteroatoms and an adjacent appended O heteroatom: ##STR5## (A is selected from hydrogen; straight or branched (C 1 -C 4 )alkyl; C 6 -aryl; substituted C 6 -aryl (substitution selected from halo, (C 1 -C 4 )alkoxy, trihalo(C 1 -C 3 )alkyl, nitro, amino, cyano, (C 1 -C 4 )alkoxycarbonyl, (C 1 -C 3 )alkylamino or carboxy); (C 7 -C 9 )aralkyl group selected from benzyl, 1-phenylethyl, 2-phenylethyl or phenylpropyl)
such as γ-butyrolactam, γ-butyrolactone, imidazolidinone or N-aminoimidazolidinone, or a six membered aromatic ring with one to three N heteroatoms such as pyridyl, pyridazinyl, pyrazinyl, sym-triazinyl, unsym-triazinyl, pyrimidinyl or (C 1 -C 3 )alkylthiopyridazinyl, or a six membered saturated ring with one or two N, O, S or Se heteroatoms and an adjacent appended O heteroatom such as 2,3-dioxo-1-piperazinyl, 4-ethyl-2,3-dioxo-1-piperazinyl, 4-methyl-2,3-dioxo-1-piperazinyl, 4-cyclopropyl-2-dioxo-1-piperazinyl, 2-dioxomorpholinyl, 2-dioxothiomorpholinyl; or --(CH 2 ) n COOR 8 where n=0-4 and R 8 is selected from hydrogen; straight or branched (C 1 -C 3 )alkyl group selected from methyl, ethyl, n-propyl or 1-methylethyl; or (C 6 -C 10 )aryl group selected from phenyl, α-naphthyl, or β-naphthyl;
R 7 is selected from hydrogen; straight or branched (C 1 -C 3 )alkyl group selected from methyl, ethyl, n-propyl or 1-methylethyl; (C 6 -C 10 )aryl group selected from phenyl, α-naphthyl or β-naphthyl; (C 7 -C 9 )aralkyl group such as benzyl, 1-phenylethyl, 2-phenylethyl or phenylpropyl; a heterocycle group selected from a five membered aromatic or saturated ring with one N, O, S or Se heteroatom optionally having a benzo or pyrido ring fused thereto: ##STR6## Z=N, O,S or Se such as pyrrolyl, N-methylindolyl, indolyl, 2-pyrrolidinyl, 3-pyrrolidinyl, 2-pyrrolinyl, tetrahydrofuranyl, furanyl, benzofuranyl, tetrahydrothienyl, thienyl, benzothienyl or selenazolyl, or a five membered aromatic ring with two N, O, S or Se heteroatoms Z5 optionally having a benzo or pyrido ring fused thereto: ##STR7## Z or Z 1 =N, O, S or Se such as imidazolyl, pyrazolyl, benzimidazolyl, oxazolyl, benzoxazolyl, indazolyl, thiazolyl, benzothiazolyl, 3-alkyl-3H-imidazo[4,5-b]pyridyl or pyridylimidazolyl, or a five membered saturated ring with one or two N, O, S or Se heteroatoms and an adjacent appended O heteroatom: ##STR8## (A is selected from hydrogen; straight or branched (C 1 -C 4 )alkyl; C 6 -aryl; substituted C 6 -aryl (substitution selected from halo, (C 1 -C 4 )alkoxy, trihalo(C 1 -C 3 )alkyl, nitro, amino, cyano, (C 1 -C 4 )alkoxycarbonyl, (C 1 -C 3 )alkylamino or carboxy); (C 7 -C 9 )aralkyl group selected from benzyl, 1-phenylethyl, 2-phenylethyl or phenylpropyl)
such as γ-butyrolactam, γ-butyrolactone, imidazolidinone or N-aminoimidazolidinone, or a six membered aromatic ring with one to three N heteroatoms such as pyridyl, pyridazinyl, pyrazinyl, sym,triazinyl, unsym-triazinyl, pyrimidinyl or (C 1 -C 3 )alkylthiopyridazinyl, or a six membered saturated ring with one or two N, O, S or Se heteroatoms and an adjacent appended O heteroatom such as 2,3-dioxo-1-piperazinyl, 4-ethyl-2,3-dioxo-1-piperazinyl, 4-methyl-2,3-dioxo-1-piperazinyl, 4-cyclopropyl-2-dioxo-1-piperazinyl, 2-dioxomorpholinyl, 2-dioxothiomorpholinyl; or --(CH 2 ) n COOR 8 where n=0-4 and R 8 is selected from hydrogen; straight or branched (C 1 -C 3 )alkyl selected from methyl, ethyl, n-propyl or 1-methylethyl; or (C 6 -C 10 )aryl selected from phenyl, α-naphthyl or β-naphthyl; with the proviso that R 6 and R 7 cannot both be hydrogen;
or R 6 and R 7 taken together are --(CH 2 ) 2 B(CH 2 ) 2 --, wherein B is selected from (CH 2 ) n and n=0-1, --NH, --N(C 1 -C 3 )alkyl [straight or branched], --N(C 1 -C 4 )alkoxy, oxygen, sulfur or substituted congeners selected from (L or D)proline, ethyl(L or D)prolinate, morpholine, pyrrolidine or piperidine; and the pharmacologically acceptable organic and inorganic salts or metal complexes.
Preferred compounds are compounds according to the above formula I and II wherein:
R is a halogen selected from bromine, chlorine, fluorine and iodine; or R=--NR 1 R 2 and when R=--NR 1 R 2 and R 1 =hydrogen,
R 2 =methyl, ethyl, n-propyl, 1-methylethyl, n-butyl, 1-methylpropyl, 2-methylpropyl or 1,1-dimethylethyl; and when R 1 =methyl or ethyl,
R 2 =methyl, ethyl, n-propyl, 1-methylethyl, n-butyl, 1-methylpropyl or 2-methylpropyl;
R 3 is selected from hydrogen; straight or branched (C 4 -C 8 )alkyl group selected from butyl, isobutyl, pentyl, hexyl, heptyl and octyl;
α-hydroxy(C 1 -C 4 )alkyl group selected from hydroxymethyl, α-hydroxyethyl, α-hydroxy-1-methylethyl and α-hydroxypropyl;
carboxyl(C 1 -C 8 )alkyl group; (C 6 -C 10 )aryl group selected from phenyl, α-naphthyl and β-naphthyl;
substituted (C 6 -C 10 )aryl group (substitution selected from hydroxy, halogen, (C 1 -C 4 )alkoxy, (C 1 -C 4 )alkoxycarbonyl and carboxy); (C 7 -C 9 )aralkyl group selected from benzyl, 1-phenylethyl, 2-phenylethyl and phenylpropyl;
substituted (C 7 -C 9 )aralkyl group [substitution selected from halo, (C 1 -C 4 )alkyl, (C 1 -C 4 )alkyl, (C 1 -C 4 )alkylsulfonyl, cyano and carboxy];
R 4 is selected from hydrogen and (C 1 -C 4 )alkyl selected from methyl, ethyl, propyl, isopropyl, butyl and isobutyl;
when R 3 does not equal R 4 the stereochemistry of the asymmetric carbon (i.e. the carbon bearing the substituent W) maybe be either the racemate (DL) or the individual enantiomers (L or D);
W is selected from hydroxylamino; (C 7 -C 12 ) straight or branched alkyl monosubstituted amino group substitution selected from heptyl, octyl, nonyl, decyl, undecyl, dodecyl and the diastereomers and enantiomers of said branched alkyl monosubstituted amino group;
(C 3 -C 8 )cycloalkyl monosubstituted amino group substitution selected from cyclopropyl, trans-1,2-dimethylcyclopropyl, cis-1,2-dimethylcyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, and the diastereomers and enantiomers of said (C 3 -C 8 )cycloalkyl monosubstituted amino group; (C 1 -C 4 ) straight or branched fluoroalkylamino group selected from 2,2,2-trifluoroethyl, 3,3,3-trifluoropropyl, 2,2-difluoropropyl and 3,3-difluorobutyl, [(C 4 -C 10 )cycloalkyl]alkyl monosubstituted amino group substitution selected from (cyclopropyl)methyl, (cyclopropyl)ethyl, (cyclobutyl)methyl, (trans-2-methylcyclopropyl)methyl, and (cis-2-methylcyclobutyl)methyl; (C 3 -C 10 )alkenyl and alkynyl monosubstituted amino group substitution selected from allyl, 3-butenyl, 2-butenyl (cis or trans), 2-pentenyl, propynyl, 4-octenyl, 2,3-dimethyl-2-butenyl and 3-methyl-2-butenyl; (C 6 -C 10 )aryl monosubstituted amino group substitution selected from phenyl and naphthyl; (C 7 -C 10 )aralkylamino group substitution selected from benzyl, 2-phenylethyl, 1-phenylethyl, 2-(naphthyl)methyl, 1-(naphthyl)methyl and phenylpropyl; straight or branched symmetrical disubstituted (C 6 -C 14 )alkylamino group substitution selected from dibutyl, diisobutyl, di-s-butyl, dipentyl, diisopentyl and di-s-pentyl; symmetrical disubstituted (C 6 -C 14 )cycloalkylamino group substitution selected from dicyclopropyl, dicyclobutyl, dicyclopentyl and di(dicyclopropyl)methyl; straight or branched unsymmetrical disubstituted (C 3 -C 14 )alkylamino group wherein the total number of carbons in the substitution is no more than 14; unsymmetrical disubstituted (C 4 -C 14 )cycloalkylamino group wherein the total number of carbons in the substitution is no more than 14; (C 2 -C 8 )azacycloalkyl and substituted (C 2 -C 8 )azacycloalkyl group substitution selected from 4-methylpiperidine, 4-hydroxypiperidine, 4-(hydroxymethyl)piperidine, 4-(aminomethyl)piperidine, cis-3,4-dimethylpyrrolidinyl, trans-3,4-dimethylpyrrolidinyl, 2-azabicyclo [2.2.1]hept-2-yl, 7-azabicyclo[2.2.1]hept-7-yl, 2-azabicyclo[2.2.2]oct-2-yl and the diastereomers and enantiomers of said (C 2 -C 8 )azacycloalkyl and substituted (C 2 -C 8 )azacycloalkyl group; substituted 1-azaoxacycloalkyl group substitution selected from 2-(C 1 -C 3 )alkylmorpholinyl, 3-(C 1 -C 3 )alkylisoxazolidinyl and tetrahydrooxazinyl; [1,n]-diazacycloalkyl and substituted [1,n]-diazacycloalkyl group-selected from piperazinyl, 2-(C 1 -C 3 )alkylpiperazinyl, 4-(C 1 -C 3 )-alkylpiperazinyl, 2,4-dimethylpiperazinyl, 4-(C 1 -C 4 )-alkoxypiperazinyl, 4-(C 6 -C 10 )aryloxypiperazinyl, 4-hydroxypiperazinyl, 2,3-diaza-3-methylbicyclo[2.2.2]oct-2-yl, 2,5-diaza-5,7-dimethylbicyclo[2.2.2]oct-2-yl and the diastereomers or enantiomers of said[1,n]-diazacycloalkyl and substituted [1,n]-di-azacycloalkyl group; 1-azathiacycloalkyl and substituted 1-azathiacycloalkyl group selected from thiomorpholinyl, 2-(C 1 -C 3 )alkylthiomorpholinyl and 3-(C 3 -C 6 )cycloalkylthiomorpholinyl; N-azolyl and substituted N-azolyl group selected from 1-imidazolyl, 1-pyrrolyl, 1-pyrazolyl, 3-(C 1 -C 3 )alkylpyrazolyl, indolyl, 1-(1,2,3-triazolyl), 4-(1,2,4-triazolyl), 1-tetrazolyl, 2-tetrazolyl and benzimidazolyl; (heterocycle)methylamino group selected from 2- or 3-furylmethylamino, 2- or 3-thienylmethylamino, 2-, 3-or 4-pyridylmethylamino, 2- or 5-pyridazinylmethylamino, 2-pyrazinylmethylamino, 2-(imidazolyl)methylamino, (benzimidazolyl)methylamino, and (benzothiazolyl)methylamino and substituted (heterocycle)methylamino group (substitution selected from straight or branched (C 1 -C 6 )alkyl); carboxy(C 2 -C 4 )alkylamino group selected from aminoacetic acid, α-aminopropionic acid, β-aminopropionic acid, α-butyric acid, and β-aminobutyric acid and the enantiomers of said carboxy(C 2 -C 4 )alkylamino group; 1,1-disubstituted hydrazino group selected from 1,1-dimethylhydrazino, N-aminopiperidinyl and 1,1-diethylhydrazino;
(C 1 -C 4 )alkoxyamino group substitution selected from methoxy, ethoxy, n-propoxy, 1-methylethoxy, n-butoxy, 2-methylpropoxy and 1,1-dimethylethoxy;
(C 3 -C 8 )cycloalkoxyamino group selected from cyclopropoxy, trans-1,2-dimethylcyclopropoxy, cis-1,2-dimethylcyclopropoxy, cyclobutoxy, and the diastereomers and enantiomers of said (C 3 -C 8 )cycloalkoxyamino group;
(C 6 -C 10 )aryloxyamino group selected from phenoxyamino, 1-naphthyloxyamino and 2-naphthyloxyamino;
(C 7 -C 11 )arylalkoxyamino group substitution selected from benzyloxy, 2-phenylethoxy, 1-phenylethoxy, 2-(naphthyl)methoxy, 1-(naphthyl)methoxy and phenylpropoxy; [β or γ-(C 1 -C 3 )acylamido]alkylamino group substitution selected from 2-(formamido)ethyl, 2-(acetamido)ethyl, 2-(propionylamido)ethyl, 2-(acetamido)propyl, 2-(formamido)propyl and the enantiomers of said [β or γ-(C 1 -C 3 )acylamido]alkylamino group; β or γ-(C 1 -C 3 )alkoxyalkylamino group substitution selected from 2-methoxyethyl, 2-ethoxyethyl, 2,2-diethoxyethyl, 2-methoxypropyl, 3-methoxypropyl, 3-ethoxypropyl, 3,3-diethoxypropyl and the enantiomers of said β or γ-(C 1 -C 3 )alkoxyalkylamino group; β, γ or δ(C 2 -C 4 )hydroxyalkylamino group substitution selected from 2-hydroxyethyl, 3-hydroxypropyl, and 4-hydroxybutyl;
or R 3 and W taken together are selected from --(CH 2 ) n (R 5 )N--, n=3-4, and --CH 2 CH(OH)CH 2 (R 5 )N-- wherein R 5 is selected from hydrogen and (C 1 -C 3 )acyl, the acyl selected from formyl, acetyl, propionyl and (C 2 -C 3 )haloacyl selected from chloroacetyl, bromoacetyl, trifluoroacetyl, 3,3,3-trifluoropropionyl and 2,3,3-trifluoropropionyl;
R 6 is selected from hydrogen; straight or branched (C 1 -C 3 )alkyl group selected from methyl, ethyl, n-propyl or 1-methylethyl; (C 6 -C 10 )aryl group selected from phenyl, α-naphthyl or β-naphthyl; (C 7 -C 9 )aralkyl group such as benzyl, 1-phenylethyl, 2-phenylethyl or phenylpropyl; a heterocycle group selected from a five membered aromatic or saturated ring with one N, O, S or Se heteroatom optionally having a benzo or pyrido ring fused thereto: ##STR9## Z=N, O, S or Se such as pyrrolyl, N-methylindolyl, indolyl, 2-pyrrolidinyl, 3-pyrrolidinyl, 2-pyrrolinyl, tetrahydrofuranyl, furanyl, benzofuranyl, tetrahydrothienyl, thienyl, benzothienyl or selenazolyl, or a five membered aromatic ring with two N, O, S or Se heteroatoms optionally having a benzo or pyrido ring fused thereto: ##STR10## Z or Z 1 =N, O, S or Se such as imidazolyl, pyrazolyl, benzimidazolyl, oxazolyl, benzoxazolyl, indazolyl, thiazolyl, benzothiazolyl, 3-alkyl-3H-imidazo[4,5-b]pyridyl or pyridylimidazolyl, or a five membered saturated ring with one or two N, O, S or Se heteroatoms and an adjacent appended O heteroatom: ##STR11## (A is selected from hydrogen; straight or branched (C 1 -C 4 )alkyl; C 6 -aryl; (C 7 -C 9 )aralkyl group selected from benzyl, 1-phenylethyl, 2-phenylethyl or phenylpropyl)
such as γ-butyrolactam, γ-butyrolactone, imidazolidinone or N-aminoimidazolidinone; or --(CH 2 ) n COOR 8 where n=0-4 and R 8 is selected from hydrogen; straight or branched (C 1 -C 3 )alkyl group selected from methyl, ethyl, n-propyl or 1-methylethyl; or (C 6 -C 10 )aryl group selected from phenyl, α-naphthyl, or β-naphthyl;
R 7 is selected from hydrogen; straight or branched (C 1 -C 3 )alkyl group selected from methyl, ethyl, n-propyl or 1-methylethyl; (C 6 -C 10 )aryl group selected from phenyl, α-naphthyl or β-naphthyl; (C 7 -C 9 )aralkyl group such as benzyl, 1-phenylethyl, 2-phenylethyl or phenylpropyl; a heterocycle group selected from a five membered aromatic or saturated ring with one N, O, S or Se heteroatom optionally having a benzo or pyrido ring fused thereto: ##STR12## Z=N, O, S or Se such as pyrrolyl, N-methylindolyl, indolyl, 2-pyrrolidinyl, 3-pyrrolidinyl, 2-pyrrolinyl, tetrahydrofuranyl, furanyl, benzofuranyl, tetrahydrothienyl, thienyl, benzothienyl or selenazolyl, or a five membered aromatic ring with two N, O, S or Se heteroatoms optionally having a benzo or pyrido ring fused thereto: ##STR13## Z or Z 1 =N, O, S or Se such as imidazolyl, pyrazolyl, benzimidazolyl, oxazolyl, benzoxazolyl, indazolyl, thiazolyl, benzothiazolyl, 3-alkyl-3H-imidazo[4,5-b]pyridyl or pyridylimidazolyl, or a five membered saturated ring with one or two N, O, S or Se heteroatoms and an adjacent appended O heteroatom: ##STR14## (A is selected from hydrogen; straight or branched (C 1 -C 4 )alkyl; C 6 -aryl; (C 7 -C 9 )aralkyl group selected from benzyl, 1-phenylethyl, 2-phenylethyl or phenylpropyl)
such as γ-butyrolactam, γ-butyrolactone, imidazolidinone or N-aminoimidazolidinone; or --(CH 2 ) n COOR 8 where n=0-4 and R 8 is selected from hydrogen; straight or branched (C 1 -C 3 )alkyl selected from methyl, ethyl, n-propyl or 1-methylethyl; or (C 6 -C 10 )aryl selected from phenyl, α-naphthyl or β-naphthyl; with the proviso that R 6 and R 7 cannot both be hydrogen;
or R 6 and R 7 taken together are --(CH 2 ) 2 B(CH 2 ) 2 --, wherein B is selected from (CH 2 ) n and n=0-1, --NH, --N(C 1 -C 3 )alkyl [straight or branched], --N(C 1 -C 4 )alkoxy, oxygen, sulfur or substituted congeners selected from (L or D)proline, ethyl(L or D)prolinate, morpholine, pyrrolidine or piperidine; and the pharmacologically acceptable organic and inorganic salts or metal complexes.
Particularly preferred compounds are compounds according to formula I and II wherein:
R is a halogen selected from bromine, chlorine, fluorine and iodine; or R=--NR 1 R 2 and when R=--NR 1 R 2 and R 1 =hydrogen,
R 2 =methyl, ethyl, n-propyl, 1-methylethyl, n-butyl, 1-methylpropyl, 2-methylpropyl or 1,1-dimethylethyl; and when R 1 =methyl or ethyl,
R 2 =methyl, ethyl, n-propyl, 1-methylethyl, n-butyl, 1-methylpropyl or 2-methylpropyl;
R 3 is selected from hydrogen; straight or branched (C 4 -C 6 )alkyl group selected from butyl, isobutyl, pentyl and hexyl; (C 6 -C 10 )aryl group selected from phenyl, α-naphthyl and β-naphthyl; (C 7 -C 9 )aralkyl group selected from benzyl, 1-phenylethyl, 2-phenylethyl and phenylpropyl;
R 4 is selected from hydrogen and (C 1 -C 3 )alkyl selected from methyl, ethyl, propyl and isopropyl;
when R 3 does not equal R 4 the stereochemistry of the asymmetric carbon (i.e. the carbon bearing the substituent W) maybe be either the racemate (DL) or the individual enantiomers (L or D);
W is selected from (C 7 -C 12 ) straight or branched alkyl monosubstituted amino group substitution selected from heptyl, octyl, nonyl, decyl, undecyl, dodecyl and the diastereomers and enantiomers of said branched alkyl monosubstituted amino group; (C 1 -C 4 ) straight or branched fluoroalkylamino group selected from 2,2,2-trifluoroethyl, 3,3,3-trifluoropropyl and 2,2-difluoropropyl; (C 3 -C 8 )cycloalkyl monosubstituted amino group substitution selected from cyclopropyl, trans-1,2-dimethylcyclopropyl, cis-1,2-dimethylcyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl and the diastereomers and enantiomers of said (C 3 -C 8 )cycloalkyl monosubstituted amino group;
[(C 4 -C 10 )cycloalkyl]alkyl monosubstituted amino group substitution selected from (cyclopropyl)methyl, (cyclopropyl)ethyl and (cyclobutyl)methyl; (C 3 -C 10 )alkenyl and alkynyl monosubstituted amino group substitution selected from allyl, propynyl, 3-butenyl, 2-butenyl (Cis or trans) and 2-pentenyl; (C 7 -C 10 )aralkylamino group substitution selected from benzyl, 2-phenylethyl, 1-phenylethyl, 2-(naphthyl)methyl, 1-(naphthyl)methyl and phenylpropyl; straight or branched symmetrical disubstituted (C 6 -C 14 )alkylamino group substitution selected from dibutyl, diisobutyl, di-s-butyl, and dipentyl; symmetrical disubstituted (C 6 -C 14 )cycloalkylamino group substitution selected from dicyclopropyl, dicyclobutyl, dicyclopentyl and dicyclopropylmethyl; straight or branched unsymmetrical disubstituted (C 3 -C 14 )alkylamino group wherein the total number of carbons in the substitution is no more than 14; unsymmetrical disubstituted (C 4 -C 14 )cycloalkylamino group wherein the total number of carbons in the substitution is no more than 14;
(C 2 -C 8 )azacycloalkyl and substituted (C 2 -C 8 )azacycloalkyl group substitution selected from 4-methylpiperidine, 4-hydroxypiperidine, 4-(hydroxymethyl)piperidine, 4-(aminomethyl)piperidine, cis-3,4-dimethylpyrrolidinyl, trans-3,4-dimethylpyrrolidinyl, and the diastereomers and enantiomers of said (C 2 -C 8 )azacycloalkyl and substituted (C 2 -C 8 )azacycloalkyl group;
substituted 1-azaoxacycloalkyl group substitution selected from 2-(C 1 -C 3 )alkylmorpholinyl and 3-(C 1 -C 3 )alkylisoxazolidinyl; [1,n]-diazacycloalkyl and substituted [1,n]-diazacycloalkyl group selected from piperazinyl, 2-(C 1 -C 3 )alkylpiperazinyl, 4-(C 1 -C 3 )alkylpiperazinyl, 2,4-dimethylpiperazinyl, 4-hydroxypiperazinyl, and the enantiomers of said [1,n]-diazacycloalkyl and substituted [1,n]-diazacycloalkyl group;
1-azathiacycloalkyl and substituted 1-azathiacycloalkyl group selected from thiomorpholinyl and 2-(C 1 -C 3 )alkylthiomorpholinyl;
(heterocycle)methylamino group selected from 2- or 3-furylmethylamino, 2- or 3-thienylmethylamino, 2-, 3-or 4-pyridylmethylamino, 2- or 5-pyridazinylmethylamino, 2-pyrazinylmethylamino, 2-(imidazolyl)methylamino and the substituted (heterocycle)methylamino group (substitution selected from straight or branched (C 1 -C 6 )alkyl); 1,1-disubstituted hydrazino group selected from 1,1-dimethylhydrazino, N-aminopiperidinyl and 1,1-diethylhydrazino;
(C 1 -C 4 )alkoxyamino group substitution selected from methoxy, ethoxy, n-propoxy, 1-methylethoxy, n-butoxy, 2-methylpropoxy and 1,1-dimethylethoxy;
(C 7 -C 11 )arylalkoxyamino group substitution selected from benzyloxy, 2-phenylethoxy, 1-phenylethoxy, 2-(naphthyl)methoxy, 1-(naphthyl)methoxy and phenylpropoxy;
[β or γ-(C 1 -C 3 )acylamido]alkylamino group substitution selected from 2-(formamido)ethyl, 2-(acetamido)ethyl, 2-(propionylamido)ethyl, 2-(acetamido)propyl and 2-(formamido)propyl and the enantiomers of said [β or γ-(C 1 -C 3 )acylamido]alkylamino group;
β or γ-(C 1 -C 3 )alkoxyalkylamino group substitution selected from 2-methoxyethyl, 2-ethoxyhyl, 2,2-diethoxyethyl, 2-methoxypropyl, 3-methoxyopyl, 3-ethoxypropyl and 3,3-diethoxypropyl and the enantiomers of said β or γ-(C 1 -C 3 )alkoxyalkyl-amino group; β, γ, or δ(C 2 -C 4 )hydroxyalkylamino group selected from 3-hydroxypropyl and 4-hydroxybutyl;
or R 3 and W taken together are selected from --(CH 2 ) n )R 5 )N--, n=3-4, and --CH 2 CH(OH)CH 2 (R 5 )N-- wherein R 5 is selected from hydrogen and (C 1 -C 3 )acyl, the acyl selected from formyl, acetyl, propionyl and (C 2 -C 3 )haloacyl selected from trifluoroacetyl, 3,3,3-trifluoropropionyl and 2,3,3-trifluoropropionyl;
R 6 is selected from hydrogen; straight or branched (C 1 -C 3 )alkyl group selected from methyl, ethyl, n-propyl or 1-methylethyl; (C 6 -C 10 )aryl group selected from phenyl, α-naphthyl or β-naphthyl; (C 7 -C 9 )aralkyl group such as benzyl, 1-phenylethyl, 2-phenylethyl or phenylpropyl; a heterocycle group selected from a five membered aromatic or saturated ring with one N, O, S or Se heteroatom optionally having a benzo or pyrido ring fused thereto: ##STR15## Z=N, O, S or Se such as pyrrolyl, N-methylindolyl, indolyl, 2-pyrrolidinyl, 3-pyrrolidinyl, 2-pyrrolinyl, tetrahydrofuranyl, furanyl, benzofuranyl, tetrahydrothienyl, thienyl, benzothienyl or selenazolyl, or a five membered aromatic ring with two N, O, S or Se heteroatoms optionally having a benzo or pyrido ring fused thereto: ##STR16## Z or Z 1 =N, O, S or Se such as imidazolyl, pyrazolyl, benzimidazolyl, oxazolyl, benzoxazolyl, indazolyl, thiazolyl, benzothiazolyl, 3-alkyl-3H-imidazo[4,5-b]pyridyl or pyridylimidazolyl; or --(CH 2 ) n COOR 8 where n=0-4 and R 8 is selected from hydrogen; straight or branched (C 1 -C 3 )alkyl group selected from methyl, ethyl, n-propyl or 1-methylethyl; or (C 6 -C 10 )aryl group selected from phenyl, α-naphthyl, or β-naphthyl;
R 7 is selected from hydrogen; straight or branched (C 1 -C 3 )alkyl group selected from methyl, ethyl, n-propyl or 1-methylethyl; (C 6 -C 10 )aryl group selected from phenyl, α-naphthyl or β-naphthyl; (C 7 -C 9 )aralkyl group such as benzyl, 1-phenylethyl, 2-phenylethyl or phenylpropyl; a heterocycle group selected from a five membered aromatic or saturated ring with one N, O, S or Se heteroatom optionally having a benzo or pyrido ring fused thereto: ##STR17## Z=N, O, S or Se such as pyrrolyl, N-methylindolyl, indolyl, 2-pyrrolidinyl, 3-pyrrolidinyl, 2-pyrrolinyl, tetrahydrofuranyl, furanyl, benzofuranyl, tetrahydrothienyl, thienyl, benzothienyl or selenazolyl, or a five membered aromatic ring with two N, O, S or Se heteroatoms optionally having a benzo or pyrido ring fused thereto: ##STR18## Z or Z 1 =N, O, S or Se such as imidazolyl, pyrazolyl, benzimidazolyl, oxazolyl, benzoxazolyl, indazolyl, thiazolyl, benzothiazolyl, 3-alkyl-3H-imidazo[4,5-b]pyridyl or pyridylimidazolyl; or --(CH 2 ) n COOR 8 where n=0-4 and R 8 is selected from hydrogen; straight or branched (C 1 -C 3 )alkyl selected from methyl, ethyl, n-propyl or 1-methylethyl; or (C 6 -Cl0)aryl selected from phenyl, α-naphthyl or β-naphthyl; with the proviso that R 6 and R 7 cannot both be hydrogen;
or R 6 and R 7 taken together are --(CH 2 ) 2 B(CH 2 ) 2 --, wherein B is selected from (CH 2 ) n and n=0-1, --NH, --N(C 1 -C 3 )alkyl [straight or branched], --N(C 1 -C 4 )alkoxy, oxygen, sulfur or substituted congeners selected from (L or D)proline, ethyl(L or D)prolinate, morpholine, pyrrolidine or piperidine; and the pharmacologically acceptable organic and inorganic salts or metal complexes.
Compounds of special interest are compound according to formula I and II wherein:
R is a halogen selected from bromine, chlorine and iodine; or R=--NR 1 R 2 and when R=--NR 1 R 2 and R 1 =methyl or ethyl,
R 2 =methyl or ethyl,
R 3 is selected from hydrogen;
R 4 is selected from hydrogen and (C 1 -C 2 )alkyl selected from methyl and ethyl;
when R 3 does not equal R 4 the stereochemistry of the asymmetric carbon (i.e. the carbon bearing the substituent W) maybe be either the racemate (DL) or the individual enantiomers (L or D);
W is selected from (C 7 -C 12 ) straight or branched alkyl monosubstituted amino group substitution selected from heptyl, octyl, nonyl, decyl, undecyl, dodecyl and the diastereomers and enantiomers of said branched alkyl monosubstituted amino group; (C 2 )fluoroalkylamino group selected from 2,2,2-trifluoroethyl and 3,3,3-trifluoropropyl;
(C 3 -C 8 )cycloalkyl monosubstituted amino group substitution selected from cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl and the diastereomers and enantiomers of said (C 3 -C 8 )cycloalkyl monosubstituted amino group; [(C 4 -C 5 )cycloalkyl]alkyl monosubstituted amino group substitution selected from (cyclopropyl)methyl and (cyclopropyl)ethyl; (C 3 -C 4 )alkenyl and alkynyl monosubstituted amino group substitution selected from allyl and propynyl; (C 2 -C 7 )azacycloalkyl and substituted (C 2 -C 7 )azacycloalkyl group substitution selected from 4-methylpiperidine, 4-hydroxypiperidine and 4-(hydroxymethyl)piperidine; substituted 1-azaoxacycloalkyl group substitution selected from 2-(C 1 -C 3 )alkylmorpholinyl; [1,n]-diazacycloalkyl and substituted [1,n]-diazacycloalkyl group selected from piperazinyl and 4-(C 1 -C 3 )alkylpiperazinyl; 1-azathiacycloalkyl and substituted 1-azathiacycloalkyl group selected from thiomorpholinyl and 2-(C 1 -C 3 )alkylthiomorpholinyl; (heterocycle)methylamino group selected from 2- or 3-thienylmethylamino and 2-, 3- or 4-pyridylmethylamino; 1,1-disubstituted hydrazino group selected from 1,1-dimethylhydrazino and N-aminopiperidinyl. [β or γ-(C 1 -C 3 )acylamido]alkylamino group substitution selected from 2-(acetamido)ethyl; β or γ-(C 1 -C 3 )alkoxyalkylamino group substitution selected from 2-methoxyethyl, 2-ethoxyethyl, 2,2-diethoxyethyl, 2-methoxypropyl and 3-methoxypropyl; β, γ or δ(C 2 -C 4 )hydroxyalkylamino selected from 4-hydroxybutyl and 3-hydroxypropyl;
or R 3 and W taken together are selected from --(CH 2 ) n )N--, n=3, and R 5 is selected from hydrogen and trifluoroacetyl;
R 6 is selected from hydrogen; straight or branched (C 1 -C 3 )alkyl group selected from methyl, ethyl, n-propyl or 1-methylethyl;
R 7 is selected from hydrogen; straight or branched (C 1 -C 3 )alkyl group selected from methyl, ethyl, n-propyl or 1-methylethyl; with the proviso that R 6 and R 7 cannot both be hydrogen;
or R 6 and R 7 taken together are --(CH 2 ) 2 B (CH 2 ) 2 --, wherein B is selected from (CH 2 ) n and n=0-1, --NH, --N(C 1 -C 3 )alkyl [straight or branched], --N(C 1 -C 4 )alkoxy, oxygen, sulfur or substituted congeners selected from (L or D)proline, ethyl(L or D)prolinate, morpholine, pyrrolidine or piperidine; and the pharmacologically acceptable organic and inorganic salts or metal complexes.
Also included in the present invention are compounds useful as intermediates for producing the above compounds of formula I and II. Such intermediates include those having the formula III: ##STR19## wherein: Y is selected from (CH 2 ) n X, n=0-5, X is halogen selected from bromine, chlorine, fluorine or iodine;
R is a halogen selected from bromine, chlorine, fluorine and iodine; or R=--NR 1 R 2 and when R=--NR 1 R 2 and R 1 =hydrogen,
R 2 =methyl, ethyl, n-propyl, 1-methylethyl, n-butyl, 1-methylpropyl, 2-methylpropyl or 1,1-dimethylethyl;
and when R 1 =methyl or ethyl,
R 2 =methyl, ethyl, n-propyl, 1-methylethyl, n-butyl, 1-methylpropyl or 2-methylpropyl;
and when R 1 =n-propyl,
R 2 =n-propyl, 1-methylethyl, n-butyl, 1-methylpropyl or 2-methylpropyl;
and when R 1 =1-methylethyl,
R 2 =n-butyl, 1-methylpropyl or 2-methylpropyl;
and when R 1 =n-butyl,
R 2 =n-butyl, 1-methylpropyl or 2-methylpropyl;
and when R 1 =1-methylpropyl,
R 2 =2-methylpropyl;
R 3 is selected from hydrogen; straight or branched (C 4 -C 8 )alkyl group selected from butyl, isobutyl, pentyl, hexyl, heptyl and octyl;
α-mercapto(C 1 -C 4 )alkyl group selected from mercaptomethyl, α-mercaptoethyl, α-mercapto-1-methylethyl and α-mercaptopropyl;
α-hydroxy-(C 1 -C 4 )alkyl group selected from hydroxymethyl, α-hydroxyethyl, α-hydroxy-1-methylethyl and α-hydroxypropyl; carboxyl(C 1 -C 8 )alkyl group;
(C 6 -C 10 )aryl group selected from phenyl, α-naphthyl and β-naphthyl; substituted (C 6 -C 10 )aryl group (substitution selected from hydroxy, halogen, (C 1 -C 4 )alkoxy, trihalo(C 1 -C 3 )alkyl, nitro, amino, cyano, (C 1 -C 4 )alkoxycarbonyl, (C 1 -C 3 )alkylamino and carboxy);
(C 7 -C 9 )aralkyl group selected from benzyl, 1-phenylethyl, 2-phenylethyl and phenylpropyl;
substituted (C 7 -C 9 )aralkyl group [substitution selected from halo, (C 1 -C 4 )alkyl, nitro, hydroxy, amino, mono-or di-substituted (C 1 -C 4 )alkylamino, (C 1 -C 4 )alkoxy, (C 1 -C 4 )alkylsulfonyl, cyano and carboxy];
R 4 is selected from hydrogen and (C 1 -C 6 )alkyl selected from methyl, ethyl, propyl, isopropyl, butyl, isobutyl, pentyl and hexyl;
when R 3 does not equal R 4 the stereochemistry of the asymmetric carbon (i.e. the carbon bearing the substituent W) maybe be either the racemate (DL) or the individual enantiomers (L or D); and the pharmacologically acceptable organic and inorganic salts or metal complexes;
Preferred compounds are compounds according to the above formula III wherein:
Y is selected from (CH 2 ) n X, n=0-5, X is halogen selected from bromine., chlorine, fluorine or iodine;
R is a halogen selected from bromine, chlorine, fluorine and iodine; or R=--NR 1 R 2 and when R=--NR 1 R 2 and R 1 =hydrogen,
R 2 =methyl, ethyl, n-propyl, 1-methylethyl, n-butyl, 1-methylpropyl, 2-methylpropyl or 1,1-dimethylethyl;
and when R 1 =methyl or ethyl,
R 2 =methyl, ethyl, n-propyl, 1-methylethyl, n-butyl, 1-methylpropyl or 2-methylpropyl;
R 3 is selected from hydrogen; straight or branched (C 4 -C 8 )alkyl group selected from butyl, isobutyl, pentyl, hexyl, heptyl and octyl;
α-hydroxy(C 1 -C 4 )alkyl group selected from hydroxymethyl, α-hydroxyethyl, α-hydroxy-1-methylethyl and α-hydroxypropyl;
carboxyl(C 1 -C 8 )alkyl group; (C 6 -C 10 )aryl group selected from phenyl, α-naphthyl and β-naphthyl;
substituted(C 6 -C 10 )aryl group (substitution selected from hydroxy, halogen, (C 1 -C 4 )alkoxy, (C 1 -C 4 )alkoxycarbonyl and carboxy); (C 7 -C 9 )aralkyl group selected from benzyl, 1-phenylethyl, 2-phenylethyl and phenylpropyl; substituted (C 7 -C 9 )aralkyl group [substitution selected from halo, (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy, (C 1 -C 4 )alkylsulfonyl, cyano and carboxy];
R 4 is selected from hydrogen and (C 1 -C 4 )alkyl selected from methyl, ethyl, propyl, isopropyl, butyl and isobutyl;
when R 3 does not equal R 4 the stereochemistry of the asymmetric carbon (i.e. the carbon bearing the substituent W) maybe be either the racemate (DL) or the individual enantiomers (L or D); and the pharmacologically acceptable organic and inorganic salts or metal complexes.
Particularly preferred compounds are compounds according to formula III wherein:
Y is selected from (CH 2 ) n X, n=0-5, X is halogen selected from bromine, chlorine, fluorine or iodine;
R is a halogen selected from bromine, chlorine, fluorine and iodine; or R=--NR 1 R 2 and when R=--NR 1 R 2 and R 1 =hydrogen,
R 2 =methyl, ethyl, n-propyl, 1-methylethyl, n-butyl, 1-methylpropyl, 2-methylpropyl or 1,1-dimethylethyl;
and when R 1 =methyl or ethyl,
R 2 =methyl, ethyl, n-propyl, 1-methylethyl, n-butyl, 1-methylpropyl or 2-methylpropyl;
R 3 is selected from hydrogen; straight or branched (C 4 -C 6 )alkyl group selected from butyl, isobutyl, pentyl and hexyl; (C 6 -C 10 )aryl group selected from 5 phenyl, α-naphthyl and β-naphthyl; (C 7 -C 9 )aralkyl group selected from benzyl, 1-phenylethyl, 2-phenylethyl and phenylpropyl;
R 4 is selected from hydrogen and (C 1 -C 3 )alkyl selected from methyl, ethyl, propyl and isopropyl;
when R 3 does not equal R 4 the stereochemistry of the asymmetric carbon (i.e. the carbon bearing the substituent W) maybe be either the racemate (DL) or the individual enantiomers (L or D); and the pharmacologically acceptable organic and inorganic salts or metal complexes.
Compounds of special interest are compound according to formula III wherein:
Y is selected from (CH 2 ) n X, n=0-5, X is halogen selected, from bromine, chlorine, fluorine or iodine;
R is a halogen selected from bromine, chlorine and iodine; or R=--NR 1 R 2 and when R=--NR 1 R 2 and R 1 =methyl or ethyl,
R 2 =methyl or ethyl,
R 3 is selected from hydrogen;
R 4 is selected from hydrogen and (C 1 -C 2 )alkyl selected from methyl and ethyl;
when R 3 does not equal R 4 the stereochemistry of the asymmetric carbon (i.e. the carbon bearing the substituent W) maybe be either the racemate (DL) or the individual enantiomers (L or D); and the pharmacologically acceptable organic and inorganic salts or metal complexes.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The novel compounds of the present invention may be readily prepared in accordance with the following schemes.
The preferred method for producing 7-(substituted)-9-[(substituted glycyl)amido]-6-demethyl-6-deoxytetracyclines or the mineral acid salts, 3, is shown in scheme I. This method uses common intermediates which are easily prepared by reacting commercially available haloacyl halides of the formula: ##STR20## wherein Y, R 3 and R 4 are as defined hereinabove and Q is halogen selected from bromine, chlorine, iodine and fluorine; with 9-amino-7-(substituted)-6-demethyl-6-deoxytetracycline or its mineral acid salt, 1, to give straight or branched 9-[(haloacyl)amido]-7-(substituted)-6-demethyl-6-deoxytetracyclines or mineral acid salts, 2, in almost quantitative yield. The above intermediates, straight or branched 9-[(haloacyl)amido]-7-(substituted)-6-demethyl-6-deoxytetracyclines or mineral acid salts, 2, react with a wide variety of nucleophiles, especially amines, having the formula WH, wherein W is as defined hereinabove, to give a new 7-(substituted)-9-[(substituted glycyl)amido]-7-(substituted)-6-demethyl-6-deoxytetracyclines or the mineral acid salts, 3 of the present invention. ##STR21##
In accordance with scheme I, 9-amino-7-(substituted)-6-demethyl-6-deoxytetracycline or its mineral acid salt, 1, is mixed with
a) a polar-aprotic solvent such as 1,3-dimethyl-3,4,5,6-tetrahydro-2(1H)pyrimidone, herein after called DMPU, hexamethylphosphoramide herein after called HMPA, dimethylformamide, dimethylacetamide, N-methylpyrrolidone, 1,2-dimethoxyethane or equivalent thereof;
b) an inert solvent such as acetonitrile, methylene chloride, tetrahydrofuran, chloroform, carbon tetrachloride, 1,2-dichloroethane, tetrachloroethane, diethyl ether, t-butyl methyl ether, isopropyl ether or equivalent thereof;
c) a base such as sodium carbonate, sodium bicarbonate, sodium acetate, potassium carbonate, potassium-bicarbonate, triethylamine, cesium carbonate, lithium carbonate or bicarbonate equivalents; and
d) a straight or branched haloacyl halide of the formula: ##STR22## wherein Y, R 3 , R 4 and Q are as hereinabove defined, such as bromoacetyl bromide, chloroacetyl chloride, 2-bromopropionyl bromide or equivalent thereof; the halo, Y, and halide, Q, in the haloacyl halide can be the same or different halogen and is selected from bromine, chlorine, iodine and fluorine; Y is (CH 2 ) n X, n=0-5, X is halogen;
e) for 0.5 to 5 hours at from room temperature to the reflux temperature of the reaction; to form the corresponding 9-[(haloacyl)amido-7-(substituted)-6-demethyl-6-deoxytetracycline, 2, or its mineral acid salt.
The intermediate, 9-[(haloacyl) amido]-7-(substituted)-6-demethyl-6-deoxytetracycline or its mineral acid salt, 2, is treated, under an inert atmosphere of helium, argon or nitrogen, with
a) a nucleophile WH such as an amine, substituted amine or equivalent thereof for example methylamine, dimethylamine, ethylamine, n-butylamine, propylamine or n,hexylamine;
b) a polar-aprotic solvent such as DMPU, HMPA dimethylformamide, dimethylacetamide, N-methylpyrrolidone or 1,2-dimethoxyethane;
c) for from 0.5-2 hours at room temperature or under reflux temperature to produce the desired 7-(substituted)-9-[(substituted glycyl)amido]-6-demethyl-6-deoxytetracycline, 3, or its mineral acid salt. ##STR23##
In accordance with Scheme II, compounds of formula 3 are N-alkylated in the presence of formaldehyde and either a primary amine such as methylamine, ethylamine, benzylamine, methyl glycinate, (L or D)alanine, (L or D)lysine of their substituted congeners; or a secondary amine such as morpholine, pyrrolidine, piperidine or their substituted congeners to give the corresponding Mannich base adduct, 4.
The 7-(substituted)-9-[(substituted glycyl)amido]-6-demethyl-6-deoxytetracyclines may be obtained as metal complexes such as aluminum, calcium, iron, magnesium, manganese and complex salts; inorganic and organic salts and corresponding Mannich base adducts using methods known to those skilled in the art (Richard C. Larock, Comprehensive Organic Transformations, VCH Publishers, 411-415, 1989). It is well known to one skilled in the art that an appropriate salt form is chosen based on physical land chemical stability, flowability, hygroscopicity and solubility. Preferably, the 7-(substituted)-9-[(substituted glycyl)amido]-6-demethyl-6-deoxytetracyclines are obtained as inorganic salt such as hydrochloric, hydrobromic, hydroiodic, phosphoric, nitric or sulfate; or organic salt such as acetate, benzoate, citrate, cysteine or other amino acids, fumarate, glycolate, maleate, succinate, tartrate, alkylsulfonate or arylsulfonate. Depending on the stoichiometry of the acids used, the salt formation occurs with the C(4)-dimethylamino group (1 equivalent of acid) or with both the C(4)-dimethylamino group and the W group (2 equivalents of acid). The salts are preferred for oral and parenteral administration.
Some of the compounds of the hereinbefore described Schemes have centers of asymmetry at the carbon bearing the W substituent. The compounds may, therefore, exist in at least two (2) stereoisomeric forms. The present invention encompasses the racemic mixture of stereoisomers as well as all stereoisomers of the compounds whether free from other stereoisomers or admixed with stereoisomers in any proportion of enantiomers. The absolute configuration of any compound may be determined by conventional X-ray crystallography.
The stereochemistry centers on the tetracycline unit (i.e. C-4, C-4a, C-5a and C-12a) remain intact throughout the reaction sequences.
BIOLOGICAL ACTIVITY
Methods for in Vitro antibacterial evaluation (Table I)
The minimum inhibitory concentration (MIC), the lowest concentration of the antibiotic which inhibits growth of the test organism, is determined by the agar dilution method using 0.1 ml Muller-Hinton II agar (Baltimore Biological Laboratories) per well. An inoculum density of 1-5×10 5 CFU/ml, and an antibiotic concentrations range of 32-0.004 microgram/ml is used. MIC is determined after the plates are incubated for 18 hours at 35° C. in a forced air incubator. The test organisms comprise strains that are sensitive to tetracycline and genetically defined strains that are resistant to tetracycline, due to inability to bind bacterial ribosomes (tetM).
E. coli in Vitro Protein Translation System (Table II)
An in vitro, cell free, protein translation system using extracts from E. coli strain MRE600 (tetracycline sensitive) and a derivative of MRE600 containing the tetM determinant has been developed based on literature methods [J. M. Pratt, Coupled Transcription-translation in Prokaryotic Cell-free Systems, Transcription and Translation, a Practical Approach, (B. D. Hames and S. J. Higgins, eds) p. 179-209, IRL Press, Oxford-Washington, 1984].
Using the system described above, the tetracycline compounds of the present invention are tested for their ability to inhibit protein synthesis in vitro. Briefly, each 10 microliter reaction contains S30 extract (a whole extract) made from either tetracycline sensitive cells or an isogenic tetracycline resistant (tetM) strain, low molecular weight components necessary for transcription and translation (i.e. ATP and GTP), a mix of 19 amino acids (no methionine), 35 S labeled methionine, DNA template (either pBR322 or pUC119), and either DMSO (control) or the novel tetracycline compound to be tested ("novel TC") dissolved in DMSO.
The reactions are incubated for 30 minutes at 37 C. Timing is initiated with the addition of the S30 extract, the last component to be added. After 30 minutes, 2.5 μl of the reaction is removed and mixed with 0.5 ml of 1N NaOH to destroy RNA and tRNA. Two ml of 25% trichloroacetic acid is added and the mixture incubated at room temperature for 15 minutes. The trichloroacetic acid precipitated material is collected on Whatman GF/C filters and washed with a solution of 10% trichloroacetic acid. The filters are dried and the retained radioactivity, representing incorporation of 35 S-methionine into polypeptides, is counted using standard liquid scintillation methods.
The percent inhibition (P.I.) of protein synthesis is determined to be: ##EQU1## In Vivo Antibacterial Evaluation
The therapeutic effects of tetracyclines are determined against an acute lethal infection with Staphylococcus aureus strain Smith (tetracycline sensitive). Female, mice, strain CD-1 (Charles River Laboratories), 20±2 grams, are challenged by an intraperitoneal injection of sufficient bacteria (suspended in hog mucin) to kill non-treated controls within 24-48 hours. Antibacterial agents, contained in 0.5 ml of 0.2% aqueous agar, are administered subcutaneously or orally 30 minutes after infection. When an oral dosing schedule is used, animals are deprived of food for 5 hours before and 2 hours after infection. Five mice are treated at each dose level. The 7 day survival ratios from 3. separate tests are pooled for calculation of median effective dose (ED 50 ).
Testing Results
The claimed compounds exhibit antibacterial activity against a spectrum of tetracycline sensitive and resistant Gram-positive and Gram-negative bacteria, especially, strains of E. coli, S. aureus and E. faecalis, containing tetM and tetD resistance determinants; and E. coli containing the tetB and tetD resistance determinants. Notable are compounds D, G, and K, as shown in Table I, which demonstrated excellent in vitro activity against tetracycline resistant strains containing the tetM resistance determinant (such as S. aureus UBMS 88-5, S. aureus UBMDS 90-1 and 90-2, E. coli UBMS 89-1 and 90-4) and tetracycline resistant strains containing tetB resistance determinants (such as E. coli UBMS 88-1 and E. coli TN10C tetB). These compounds also have good activity against E. coli tetA, E. Coli tetC and E. coli tetD and are equally as effective as minocycline against susceptible strains and are superior to that of minocycline against a number of recently isolated bacteria from clinical sources (Table I).
Minocycline and compounds B, C, D, G and H are assayed in vitro for their ability to inhibit protein synthesis taking place on either wild type or tetM protected ribosomes using a coupled transcription and translation system. All compounds are found to effectively inhibit protein synthesis occuring on wild type ribosomes, having equivalent levels of activity. Minocycline is unable to inhibit protein synthesis occurring on tetM protected ribosomes. In contrast, compounds B, C, D, G and H are effective at inhibiting protein synthesis occurring on tetM protected ribosomes (Table II).
Compounds B, C, D, G and H bind reversibly to its target (the ribosome) since bacterial growth resumes when the compound is removed from the cultures by washing of the organism. Therefore, the ability of these compounds to inhibit bacterial growth appears to be a direct consequence of its ability to inhibit protein synthesis at the ribosome level.
The activity of compound G against tetracycline susceptible organisms is also demonstrated in vivo in animals infected with S. aureus Smith with ED 50 's between 1-2 mg/kg when administered intravenously, and ED 50 's of 4-8 mg/kg when given orally.
The improved efficacy of compounds D, G and K is demonstrated by the in vitro activity against isogenic strains into which the resistance determinants, such as tetM and tetB, were cloned (Table I); and the inhibition of protein synthesis by tetM ribosomes (Table II).
As can be seen from Table I and II, compounds of the invention may also be used to prevent or control important veterinary diseases such as diarrhea, urinary tract infections, infections of skin and skin structure, ear, nose and throat infections, wound infections, mastitis and the like.
______________________________________COMPOUND LEGEND FOR TABLES______________________________________A [7S-(7alpha,10aalpha)]-N-[9-(Aminocarbonyl)- 4,7-bis(dimethylamino)-5,5a,5,5a,7,10,10a, 12-octahydro-1,8,10a,11-tetrahydroxy-10,12- dioxo-2-naphthacenyl]-1-(trifluoroacetyl)-2- pyrrolidinecarboxamide dihydrochlorideB [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- amino)-1,4,4a,5,5a,6,11,12a-octahydro-3,10, 12,12a-tetrahydroxy-9-[[[(2-(methoxyethyl)- amino]acetyl]amino]-1,11-dioxo-2-naphthacene- carboxamide dihydrochlorideC [4S-(4alpha,12aalpha)]-9-[[[(2,2-Diethoxy- ethyl)amino]acetyl]amino]-4,7-bis(dimethyl- amino)-1,4,4a,5,5a,6,11,12a-octahydro-3,10, 12,12a-tetrahydroxy-1,11-dioxo-2-naphthacene- carboxamide dihydrochlorideD [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- amino)-1,4,4a,5,5a,6,11,12a-octahydro-3,10, 12,12a-tetrahydroxy-1,11-dioxo-9-[[(2-pro- penylamino)acetyl]amino]-2-naphthacenecarbox- amide dihydrochlorideE [4S-(4alpha,12aalpha)]-4,7-bis(dimethyl- amino)-1,4,4a,5,5a,6,11,12a-octahydro-3,10, 12,12a-tetrahydroxy-1,11-dioxo-9-[[[(2- pyridinylmethyl)amino]acetyl]amino-2-naphtha- cenecarboxamide dihydrochlorideF [7S-(7alpha,10aalpha)]-N-[9-(Aminocarbonyl)- 4,7-bis(dimethylamino)-5,5a,6,6a,7,10,10a,12- octahydro-1,8,10a,11-tetrahydroxy-10,12- dioxo-2-naphthacenyl]-4-thiomorpholineacet- amide dihydrochlorideG [7S-(7alpha,10aalpha)]-N-[9-(Aminocarbonyl)- 4,7-bis(dimethylamino)-5,5a,6,6a,7,10,10a,12- octahydro-1,8,10a,11-tetrahydroxy-10,12- dioxo-2-naphthacenyl]-4-methyl-1-piperidine- acetamide dihydrochlorideH [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- amino)-1,4,4a,5,5a,6,11,12a-octahydro-3,10, 12,12a-tetrahydroxy-9-[[[(3-methoxypropyl)- amino]acetyl]amino]-1,11-dioxo-2-naphthacene- carboxamide dihydrochlorideI 7[7S-(7alpha,10aalpha)]-N-[9-(Aminocarbonyl)- 4,7-bis(dimethylamino)-5,5a,6,6a,7,10,10a,12- octahydro-1,8,10a,11-tetrahydroxy-10,12- dioxo-2-naphthacenyl]-4-methyl-1-piperazine- acetamide dihydrochlorideJ [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- amino)-9-[[(heptylamino)acetyl]amino]-1,4,4a, 5,5a,6,11,12a-octahydro-3,10,12,12a-tetra- hydroxy-1,11-dioxo-2-naphthacenecarboxamide dihydrochlorideK [4S-(4alpha,12aalpha)]--9-[[(Cyclopropyl- methyl)amino]acetyl]amino]-4,7-bis(dimethyl- amino)-1,4,4a,5,5a,6,11,12a-octahydro-3,10, 12,12a-tetrahydroxy-1,11-dioxo-2-naphthacene- carboxamide dihydrochlorideL [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- amino)-1,4,4a,5,5a,6,11,12a-octahydro-3,10, 12,12a-tetrahydroxy-1,11-dioxo-9-[[(undecyl- amino)acetyl]amino]-2-naphthacenecarboxamide dihydrochlorideM [4S-(4alpha,12aalpha)]-9-[(Bromoacetyl)- amino]-4,7-bis(dimethylamino)-1,4,4a,5,5a,6, 11,12a-octahydro-3,10,12,12a-tetrahydroxy-1, 11-dioxo-2-naphthacenecarboxamide dihydro- chlorideN TetracyclineO MinocyclineP [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- amino)-1,4,4a,5,5a,6,11,12a-octahydro-3,10,- 12,12a-tetrahydroxy-9-[[[(2-hydroxyethyl)- amino]acetyl]amino]-1,11-dioxo-2-naphthacene- carboxamide monohydrochlorideQ [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- amino)-1,4,4a,5,5a,6,11,12a-octahydro-3,10,- 12,12a-tetrahydroxy-9-[[[(2-hydroxyethyl)- methylamino]acetyl]amino-1,11-dioxo-2- naphthacenecarboxamideR [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl-4- amino-1-amino)-1,4,4a,5,5a,6,11,12a-octa- hydro-3,10,12,12a-tetrahydroxy-9-[[[(4- (hydroxybutyl)amino]acetyl]amino]-1,11-dioxo- 2-naphthacenecarboxamideS [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- amino)-1,4,4a,5,5a,6,11,12a-octahydro-3,10,- 12,12a-tetrahydroxy-1,11-dioxo-9-[[[2,2,2- trifluoroethyl)amino]acetyl]amino-2-naphtha- cenecarboxamideT [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- amino)-9-[[[(2-fluoroethyl)amino]acetyl]- amino]-1,4,4a,5,5a,6,11,12a-octahydro- 3,10,12,12a-tetrahydroxy-1,11-dioxo-2- naphthacenecarboxamideU [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- amino)-1,4,4a,5,5a,6,11,12a-octahydro- 3,10,12,12a-tetrahydroxy-1,11-dioxo-9- [[[[2-(1-piperidinyl)ethyl]amino]acetyl]- amino]-2-naphthacenecarboxamideV [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- amino)-1,4,4a,5,5a,6,11,12a-octahydro-3,10,- 12,12a-tetrahydroxy-9-[[[methyl-2-propynyl- amino]acetyl]amino]-1,11-dioxo-2-naphtha- cenecarboxamideW [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- amino)-1,4,4a,5,5a,6,11,12a-octahydro-3,10,- 12,12a-tetrahydroxy-hydroxy-1,11-dioxo-9- [[(1-piperidinylamino)acetyl]amino]-2- naphthacenecarboxamideX [4S-(4-alpha,12aalpha)]-4,7-Bis(dimethyl- amino)-1,4,4a,5,5a,6,11,12a-octahydro-3,10,- 12,12a-tetrahydroxy-1,11-dioxo-9-[[[(phenyl- methoxy)amino]acetyl]amino]-2-naphthacene- carboxamide______________________________________
TABLE I__________________________________________________________________________ANTIBACTERIAL ACTIVITY OF 9-[(SUBSTITUTED GLYCYL)AMIDO]-6-DEMETHYL-6-DEOXYTETRACYCLINESMIC (μg/ml)__________________________________________________________________________ CompoundOrganism A B C D E F G H I J K L M N O__________________________________________________________________________E. coli UBMS 88-1 Tet B 8 2 16 1 16 >32 2 2 8 2 0.5 32 >32 >32 16E. coli J3272 Tet sens. 8 2 8 0.5 NT >32 1 1 NT NT NT NT 16 0.5 0.5E. coli MC 4100 Tet sens. NT NT NT NT 2 NT NT NT 1 1 0.12 2 NT NT NTE. coli PRP1 Tet A >32 8 >32 8 32 >32 2 4 16 2 4 32 >32 32 4E. coli MC 4100 TNIOC 8 2 8 1 NT >32 2 2 NT NT NT NT >32 >32 8Tet BE. coli J3272 Tet C 8 4 16 1 16 >32 1 1 8 2 0.5 32 >32 >32 2E. coli UBMS 89-1 Tet M 8 2 4 0.5 8 >32 0.5 2 8 0.5 0.5 16 4 8 8E. coli UBMS 89-2 Tet sens. 8 2 8 0.5 16 >32 2 1 8 2 0.5 16 32 1 0.5E. coli J2175 8 2 8 0.5 16 >32 1 1 8 2 0.5 16 32 1 0.5E. coli BAJ9003 IMP MUT 1 0.25 0.5 0.12 1 0.5 0.12 0.12 0.5 0.25 0.12 1 0.25 0.25 0.03E. coli UBMS 90-4 Tet M NT 2 4 0.5 8 >32 1 1 8 2 0.5 32 NT 16 >32E. coli UBMS 90-5 4 2 8 0.5 16 >32 2 1 8 2 0.5 16 16 1 0.5E. coli #311 (MP) 8 2 8 0.5 8 >32 1 1 8 2 0.5 8 8 1 0.25E. coli ATCC 25922 8 2 8 0.5 8 32 1 1 8 2 0.5 8 16 0.5 0.5E. coli J3272 Tet D 2 1 4 0.25 8 16 0.25 0.5 4 2 0.25 32 32 >32 8S. mariescens FPOR 8733 >32 >32 >32 8 >32 >32 16 16 >32 16 8 >32 >32 32 2X. maltophilia NEMC 87210Ps. acrygubisa ATCC 27853 >32 >32 >32 16 >32 >32 32 32 >32 >32 16 >32 >32 8 8S. aureus NEMC 8769 1 0.5 0.25 0.12 8 0.25 0.12 0.25 0.5 no growth 1 0.5 0.12 0.03 <0.015S. aureus UBMS 88-4 4 0.5 1 0.25 8 1 0.5 1 2 0.5 0.5 0.5 0.5 0.06 0.03S. aureus UBMS 88-5 Tet M 4 1 1 0.25 8 1 0.5 0.5 4 0.5 1 16 1 >32 4S. aureus UBMS 88-7 Tet K 16 16 8 8 32 4 0.5 8 16 1 4 2 2 >32 0.12S. aureus UBMS 90-1 Tet M 8 2 1 0.5 8 1 0.5 2 8 1 1 16 1 32 4S. aureus UBMS 90-3 1 0.5 0.5 0.25 4 1 0.5 0.5 2 0.5 0.5 0.5 0.5 0.06 0.03S. aureus UBMS 90-2 Tet M 2 0.5 1 0.25 8 1 0.5 0.5 2 0.5 0.5 4 0.5 32 2S. aureus IVES 2943 16 32 8 8 >32 4 0.5 16 >32 0.5 8 16 4 >32 2S. aureus ROSE (MP) 32 32 16 8 >32 8 1 16 >32 2 8 16 8 >32 0.5S. aureus ATCC 29213 4 1 1 0.25 8 1 0.5 1 2 0.5 1 1 0.5 0.06 0.03S. hemolyticus AVHAH 88-3 8 2 2 0.5 16 4 1 2 16 2 2 8 2 0.5 0.12Enterococcus 12201 0.5 0.5 1 0.25 4 1 0.25 0.5 2 0.5 0.25 4 1 32 8E. faecalis ATCC 29212 2 0.25 0.5 0.12 2 0.25 0.12 0.25 1 0.25 0.25 2 0.5 8 1__________________________________________________________________________ CompoundOrganism P Q R S T U V W X__________________________________________________________________________E. coli UBMS 88-1 Tet B >32 32 >32 32 16 >32 >32 >32 >32E. coli J3272 Tet sens. NT NT NT NT NT NT NT NT NTE. coli MC 4100 Tet sens. 4 4 8 16 2 4 32 32 4E. coli PRP1 Tet A >32 >32 >32 >32 >32 >32 >32 >32 >32E. coli MC 4100 TNIOC Tet B >32 >32 >32 >32 16 32 >32 >32 >32E. coli J3272 Tet C >32 >32 >32 >32 >32 16 >32 >32 >32E. coli UBMS 89-1 Tet M >32 32 32 32 8 16 >32 >32 16E. coli UBMS 89-2 Tet sens. >32 32 32 >32 16 32 >32 >32 >32E. coli J2175 32 32 32 >32 16 32 >32 >32 >32E. coli BAJ9003 IMP MUT 2 2 4 1 1 2 4 16 1E. coli UBMS 90-4 Tet M 32 16 32 >32 8 16 >32 >32 >32E. coli UBMS 90-5 32 32 32 >32 16 16 >32 >32 >32E. coli #311 (MP) 16 32 32 >32 16 16 >32 >32 16E. coli ATCC 25922 16 32 32 >32 8 16 >32 >32 16E. coli J3272 Tet D 16 32 8 >32 8 8 >32 >32 16S. mariescens FPOR 8733 >32 16 8 >32 >32 >32 >32 >32 >32X. maltophilia NEMC 87210 >32 8 8 16 16 16 32 >32 16Ps. acruginosa ATCC 27853 >32 >32 >32 >32 >32 >32 >32 >32 >32S. aureus NEMC 8769 4 8 8 4 4 8 4 >32 1S. aureus UBMS 88-4 8 8 8 4 4 8 4 >32 1S. aureus UBMS 88-5 Tet M 32 16 32 8 4 16 8 >32 2S. aureus UBMS 88-7 Tet K 32 32 32 32 >32 16 32 >32 4S. aureus UBMS 90-1 Tet M 32 32 32 16 4 32 16 >32 2S. aureus UBMS 90-3 8 8 8 4 2 8 4 16 1S. aureus UBMS 90-2 Tet M 16 16 16 4 4 8 8 >32 2S. aureus IVES 2943 >32 >32 >32 >32 >32 >32 >32 >32 8S. aureus ROSE (MP) >32 >32 >32 >32 >32 >32 >32 >32 16S. aureus SMITH (MP) 4 8 8 1 1 8 4 16 0.5S. aureus IVES 1 983 >32 >32 >32 >32 >32 >32 >32 >32 8S. aureus ATCC 29213 8 16 16 4 4 8 4 32 1S. hemolyticus AVHAH 88-3 32 16 32 16 8 32 32 >32 4Enterococcus 12201 8 4 8 4 2 8 8 >32 4E. faecalis ATCC 29212 4 4 8 2 1 8 4 >32 1__________________________________________________________________________ NT = Not tested
TABLE II______________________________________In Vitro Trancription and TranslationSensitivity to Tetracycline Compounds % InhibitionCompound Conc. Wild Type S30 TetM S30______________________________________B 1.0 mg/ml 98 97 0.25 mg/ml 96 95 0.06 mg/ml 92 91C 1.0 mg/ml 98 96 0.25 mg/ml 95 84 0.06 mg/ml 88 65D 1.0 mg/ml 99 98 0.25 mg/ml 98 96 0.06 mg/ml 93 83G 1.0 mg/ml 99 99 0.25 mg/ml 97 92 0.06 mg/ml 90 83H 1.0 mg/ml 99 98 0.25 mg/ml 96 94 0.06 mg/ml 88 85O 1.0 mg/ml 98 68 0.25 mg/ml 89 43 0.06 mg/ml 78 0______________________________________
When the compounds are employed as antibacterials, they can be combined with one or more pharmaceutically acceptable carriers, for example, solvents, diluents and the like, and may be administered orally in such forms as tablets, capsules, dispersible powders, granules, or suspensions containing, for example, from about 0.05 to 5% of suspending agent, syrups containing, for example, from about 10 to 50% of sugar, and elixirs containing for example, from about 20 to 50% ethanol and the like, or parenterally in the form of sterile injectable solutions or suspensions containing from about 0.05 to 5% suspending agent in an tonic medium. Such pharmaceutical preparations may contain, for example, from about 25 to about 90% of the active ingredient in combination with the carrier, more usually between about 5% and 60% by weight.
An effective amount of compound from 2.0 mg/kg of body weight to 100.0 mg/kg of body weight should be administered one to five times per day via any typical route of administration including but not limited to oral, parenteral (including subcutaneous, intravenous, intramuscular, intrasternal injection or infusion techniques), topical or rectal, in dosage unit formulations containing conventional non-toxic pharmaceutically acceptable carriers, adjuvants and vehicles. It will be understood, however, that the specific dose level and frequency of dosage for any particular patient may be varied and will depend upon a variety of factors including the activity of the specific compound employed, the metabolic stability and length of action of that compound, the age, body weight, general health, sex, diet, mode and time of administration, rate of excretion, drug combination, the severity of the particular condition, and the host undergoing therapy.
These active compounds may be administered orally as well as by intravenous, intramuscular, or subcutaneous routes. Solid carriers include starch, lactose, dicalcium phosphate, microcrystalline cellulose, sucrose and kaolin, while liquid carriers include sterile water, polyethylene glycols, non-ionic surfactants and edible oils such as corn, peanut and sesame oils, as are appropriate to the nature of the active ingredient and the particular form of administration desired. Adjuvants customarily employed in the preparation of pharmaceutical compositions may be advantageously included, such as flavoring agents, coloring agents, preserving agents, and antioxidants, for example, vitamin E, ascorbic acid, BHT and BHA.
The preferred pharmaceutical compositions from the standpoint of ease of preparation and administration are solid compositions, particularly tablets and hard-filled or liquid-filled capsules. Oral administration of the compounds is preferred.
These active compounds may also be administered parenterally or intraperitoneally. Solutions or suspensions of these active compounds as a free base or pharmacologically acceptable salt can be prepared in glycerol, liquid, polyethylene glycols and mixtures thereof in oils. Under ordinary conditions of storage and use, these preparations contain a preservative to prevent the growth of microorganisms.
The pharmaceutical forms suitable for injectable use include sterile aqueous solutions or dispersions and sterile powders for the extemporaneous preparation of sterile injectable solutions or dispersions. In all cases, the form must be sterile and must be fluid to the extent that easy syringability exists. It must be stable under the conditions of manufacture and storage and must be preserve against the contaminating action of micoorganisms such as bacterial and fungi. The carrier can be a solvent or dispersion medium containing, for example, water, ethanol, polyol (e.g., glycerol, propylene glycol and liquid polyethylene glycol), suitable mixtures thereof, and vegetable oil.
The invention will be more fully described in conjunction with the following specific examples which are not be construed as limiting the scope of the invention.
EXAMPLE 1
[4S-(4alpha,12aalpha)]-9-[(Chloroacetyl)amino]-4,7-bis(dimethylamino)-1,4,4a,5,5a,6,11,12a-octahydro-3,10,12,12a-tetrahydroxy-1,11-dioxo-2-naphthacenecarboxamide dihydrochloride
To a room temperature solution of 0.334 g of 9-amino-4,7-bis(dimethyamino)-6-demethyl-6-deoxytetracycline disulfate, 6 ml of 1,3-dimethyl-3,4,5,6-tetrahydro-2(1H)-pyrimidinone, hereinafter called DMPU, and 2 ml of acetonitrile is added 0.318 g of sodium carbonate. The mixture is stirred for 5 minutes followed by the addition of 0.068 g of chloroacetyl chloride. The reaction is stirred for 30 minutes, filtered, and the filtrate added dropwise to 100 ml of diethyl ether, containing 1 ml of 1M hydrochloric acid in diethyl ether. The resulting solid is collected and dried to give 0.340 g of the desired intermediate.
MS(FAB): m/z 549 (M+H).
EXAMPLE 2
[4S-(4alpha,12aalpha)]-9-[(Bromoacetyl)amino]-4,7-bis(dimethylamino)-1,4,4a,5,5a,6,11,12a-octahydro-3,10,12,12a-tetrahydroxy-1,11-dioxo-2-naphthacenecarboxamide monohydrobromide
The title compound is prepared by the procedure of Example 1, using 6.68 g of 9-amino-4,7-bis(dimethylamino)-6-demethyl-6-deoxytetracycline disulfate, 50 ml of DMPU, 30 ml of acetonitrile, 6.68 g of sodium carbonate and 0.215 g of bromoacetyl bromide. 5.72 g of the desired intermediate is obtained.
MS(FAB): m/z 593 (M+H).
EXAMPLE 3
[4S-(4alpha,12aalpha)]-9-[(2-Bromo-1-oxopropyl)amino]-4,7-bis(dimethylamino)-1,4,4a,5,5a,6,11,12a-octahydro-3,10,12,12a-tetrahydroxy-1,11-dioxo-2-naphthacenecarboxamide sulfate
The title compound is prepared by the procedure of Example 1, using 1.00 g of 9-amino-4,7-bis(dimethylamino)-6-demethyl-6-deoxytetracycline disulfate, 1.0 g of sodium carbonate and 0.648 g of 2-bromopropionyl bromide to give 0.981 g of the desired product.
MS(FAB): m/z 607 (M+H).
EXAMPLE 4
[4S-(4alpha,12aalpha)]-9-[(4-Bromo-1-oxobutyl)amino]-4,7-bis(dimethylamino)-1,4,4a,5,5a,6,11,12a-octahydro-3,10,12,12a-tetrahydroxy-1,11-dioxo-2-naphthacenecarboxamide dihydrochloride
The title compound is prepared by the procedure of Example 1, using 1.34 g of 9-amino-4,7-bis(dimethylamino)-6-demethyl-6-deoxytetracycline disulfate, 1.3 of sodium carbonate, 24 ml of DMPU, 8 ml of acetonitrile and 0.389 g of 4-bromobutyryl chloride to give 1.45 g of the desired product.
EXAMPLE 5
[7S-(7alpha,10aalpha)]-N-[9-(Aminocarbonyl)-4,7-bis(dimethylamino)-5,5a,6,7,10,10a,12-octahydro-1,8,10a,11-tetrahydroxy-10,12-dioxo-2-naphthacenyl]-1-trifluoroacetyl)-2-pyrrolidinecarboxamide dihydrochloride
The title compound is prepared by the procedure of Example 1, using 0.334 g of 9-amino-4,7-bis(dimethylamino)-6-demethyl-6-deoxytetracycline disulfate, 10 ml of DMPU, 2 ml of acetonitrile, 0.34 g of sodium carbonate and 7.5 ml of 0.1M (S)-(-)-N-(trifluoroacetyl)prolyl chloride to give 0.292 g of the desired product.
MS(FAB): m/z 666 (M+H).
EXAMPLE 6
4S-(4alpha,12aalpha)]-9-[[[(Cyclopropylmethyl)amino]acetyl]amino]-4,7-bis(dimethylamino)-1,4,4a,5,5a,6,11,12-a-octahydro-3,10,12,12a-tetrahydroxy-1,11-dioxo-2-naphthacenecarboxamide dihydrochloride
A mixture Of 0.20 g of product from Example 2, 0.50 g of (aminomethyl)cyclopropane and 5 ml of DMPU, under Argon, is stirred at room temperature for 1 hour. The excess amine is removed in vacuo and the residue diluted with a small volume of methyl alcohol. The diluted reaction solution is added dropwise to a mixture of diethyl ether and 5 ml of 2-propanol. 1M Hydrochloric acid in diethyl ether is added until a solid is formed. The resulting solid is collected and dried to give 0.175 g of the desired product.
MS(FAB): m/z 584 (M+H) .
Substantially following the methods described in detail herein above in Example 6, the compounds of this invention listed below in Examples 7-16 are prepared.
__________________________________________________________________________Example Starting Material MS(FAB):# Name Prod. of Exp. Reactant Rx Time m/z__________________________________________________________________________ 7 [4S-(4alpha,12aalpha)]-9-[[[(2,2- 2 or 1 2,2-Diethoxy- 3 hrs. 646(M+H)Diethoxyethyl)amino]acetyl]amino]-4,7- ethylaminebis(dimethylamino)-1,4,4a,5,5a,6,11,-12a-octahydro-3,10,12,12a-tetrahydroxy-1,11-dioxo-2-naphthacenecarboxamidedihydrochloride 8 [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- 2 or 1 2-Methoxy- 2 hr. 588(M+H)amino)-1,4,4a,5,5a,6,11,12a-octahydro- ethylamine3,10,12,12a-tetrahydroxy-9-[[[2-(methoxy-ethyl)amino]acetyl]amino]-1,11-dioxo-2-naphthacenecarboxamide dihydrochloride 9 [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- 2 or 1 Allylamine 2 hr. 570(M+H)methylamino)-1,4,4a,5,5a,6,11,12a-octa-hydro-3,10,12,12a-tetrahydroxy-1,11-dioxo-9-[[(2-propenylamino)acetyl]amino]-2-naphthacenecarboxamide dihydrochloride10 [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- 2 or 1 3-Methoxy- 2 hr. 602(M+H)amino)-1,4,4a,5,5a,6,11,12a-octahydro- propylamine3,10,12,12a-tetrahydroxy-9-[[[(3-methoxy-propyl)amino]acetyl]amino]-1,11-dioxo-2-naphthacenecarboxamide dihydrochloride11 [7S-(7alpha,10aalpha)]-N-[9-(Aminocar- 2 Thiomorpholine 3 hr. 616(M+H)bonyl)-4,7-bis(dimethylamino)-5,5a,6,6a,7,10,10a,12-octahydro-1,8,10a,11-tetra-hydroxy-10,12-dioxo-2-naphthacenyl]-4-thiomorpholineacetamide dihydrochloride12 [7S-(7alpha,10aalpha)]-N-[9-(Amino- 2 4-Methylpiperi- 2 hrs. 612(M+H)carbonyl)-4,7-bis(dimethylamino)-5,5a,- dine6,6a,7,10,10a,12-octahydro-1,8,10a,11-tetrahydroxy-10,12-dioxo-2-naphthacenyl]-4-methyl-1-piperidineacetamidedihydrochloride13 [7S-(7alpha,10aalpha)]-N-[9-(Aminocar- 2 4-methyl-1- 0.75 hr. 613(M+H)bonyl)-4,7-bis(dimethylamino)-5,5a,6,- piperazine6a,7,10,10a,12-octahydro-1,8,10a,11-tetrahydroxy-10,12-dioxo-2-naphtha-cenyl]-4-methyl-1-piperazineacetamidedihydrochloride14 [4S-(4alpha,12aalpha)]-4,7-Bis(di- 2 N-Heptylamine 2 hr. 628(M+H)methylamino)-9-[[(heptylamino)acetyl]amino]-1,4,4a,5,5a,6,11,12a-octahydro-3,10,12,12a-tetrahydroxy-1,11-dioxo-2-naphthacenecarboxamide dihydrochloride15 [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- 2 Undecylamine 3.5 hr. 684(M+H)amino)-1,4,4a,5,5a,6,11,12a-octahydro-3,10,12,12a-tetrahydroxy-1,11-dioxo-9-[[(undecylamino)acetyl]amino]-2-naphthacenecarboxamide dihydrochloride16 [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- 2 2-(Aminomethyl) 1.5 hr. 621(M+H)amino)-1,4,4a,5,5a,6,11,12a-octahydro- pyridine3,10,12,12a-tetrahydroxy-1,11-dioxo-9-[[[(2-pyridinylmethyl)amino]acetyl]amido]-2-naphthacenecarboxamide dihydrochloride__________________________________________________________________________
EXAMPLE 17
[4S-(4alpha,12aalpha)]-4,7-Bis(dimethylamino)-1,4,4a,5,5a,6,11,12a-octaheydro-3,10,12,12a-tetrahydroxy-9-[[[(2-hydroxyethyl]amino]acetyl]amino1,11-dioxo-2-naphthacenecarboxamide monohydrochloride
To a solution of 0.10 g of product from Example 7A in 2 ml of 1,3-dimethyl-2-imidazolidinone is added 0.70 ml of 2-amino-1-ethanol. The solution is stirred at room temperature for 20 minutes, added to 100 ml of diethyl ether and the resulting precipitate collected to give 0.055 g of the desired product.
MS(FAB): m/z 574 (M+H).
Substantially following the method described in detail hereinabove in Example 17, the compounds of this invention listed below in Examples 18-24 are prepared.
__________________________________________________________________________Example Starting Material MS(FAB):# Name Prod. of Exp. Reactant Rx Time m/z__________________________________________________________________________18 [4S-(4alpha,12aalpha)]-4,7-Bis(di- 7A 4-methylamino- 0.5 hrs. 588(M+H)methylamino)-1,4,4a,5,5a,6,11,12a-octa- 1-butanolhydro-3,10,12,12a-tetrahydroxy-9-[[[(2-hydroxyethyl)methylamino]acetyl]amino-1,11-dioxo-2-naphthacenecarboxamide19 [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- 7A 4-amino-1- 0.5 hr. 602(M+H)amino)-1,4,4a,5,5a,6,11,12a-octahydro- butanol3,10,12,12a-tetrahydroxy-9-[[[(4-(hydroxy-butyl)amino]acetyl]amino]-1,11-dioxo-2-naphthacenecarboxamide20 [4S-(4alpha,12aalpha)]-4,7-Bis(di- 7A 2,2,2-tri- 2 hr. 612(M+H)methylamino)-1,4,4a,5,5a,6,11,12a-octa- fluoromethyl-hydro-3,10,12,12a-tetrahydroxy-1,11- aminedioxo-9-[[[2,2,2-trifluoroethyl)amino]-acetyl]-2-naphthacenecarboxamide21 [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- 7A 2-fluoro- 2 hr. 576(M+H)amino)-9-[[[(2-fluoroethyl)amino]acetyl]- ethylamineamino]-1,4,4a,5,5a,6,11,12a-octahydro-3,10,12,12a-tetrahydroxy-1,11-dioxo-2-naphthacenecarboxamide22 [4S-(4alpha,12aalpha)]-4,7-Bis(dimethyl- 7A 1-(2-amino- 2 hr. 627(M+H)amino)-1,4,4a,5,5a,6,11,12a-octahydro- ethyl)pyrro-3,10,12,12a-tetrahydroxy-1,11-dioxo-9- lidine[[[[2-(1-piperidinyl)ethyl]amino]acetyl]-amino]-2-naphthacenecarboxamide23 [4S-(4alpha,12aalpha)]-4,7-Bis(di- 7A N-methylpro- 2 hrs. 581(M+H)methylamino)-1,4,4a,5,5a,6,11,12a-octa- pargylaminehydro-3,10,12,12a-tetrahydroxy-9-[[[methyl-2-propynylamino]acetyl]amino]-1,11-dioxo-2-naphthacenecarboxamide24 [4S-(4alpha,12aalpha)]-4,7-Bis(di- 7A 1-amino- 2 hrs. 613(M+H)methylamino)-1,4,4a,5,5a,6,11,12a-octa- piperidinehydro-3,10,12,12a-tetrahydroxy-1,11-dioxo-9-[[(1-piperidinylamino)acetyl]-amino]-2-naphthacenecarboxamide__________________________________________________________________________
EXAMPLE 25
[4S-(4-alpha,12aalpha)]-4,7-Bis(dimethylamino)-1,4,4a,5,5a,6,11,12a-octabydro-3,10,12-12a-tetrahydroxy-1,11-dioxo-9-[[[(phenylmethoxy)amino]acetyl]amino]-2-naphthacenecarboxamide
To 0.50 g of O-benzylhydroxylamine and 2.5 ml of 1,3-dimethyl-2-imidazolidinone is added 0.80 g of sodium bicarbonate. The mixture is stirred at room temperature for 2 hours, filtered and the filtrate added to 0.10 g of product from 7A. The reaction solution is stirred at room temperature for 2 hours and then added to 100 ml of diethyl ether. The resulting precipitate is collected and dried to give 0.90 g of the desired product.
MS(FAB): m/z 636 (M+H). | The invention provides compounds of the formula: ##STR1## wherein R, R 3 , R 4 and W are defined in the specification. These compounds are useful as antibiotic agents. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to athletic mouth guards. More particularly, the present invention relates to apparatus, systems and methods for securing mouth guards to an athlete's helmet that maintains the integrity of the mouth guard.
BACKGROUND OF THE INVENTION
[0002] The Center for Disease Control and Prevention (CDC) estimates that more than 3.8 million concussions and sports-related mild traumatic brain injuries (“MTBI”) occur each year. Concussions, and in many instances, mild traumatic brain injuries, particularly when repeated multiple times, significantly threaten the long-term health of an athlete. The health care costs associated with sports-related traumatic brain injuries are estimated to be in the hundreds of millions of dollars annually.
[0003] As is well known in the art, a concussion is an alteration of consciousness, disturbance in vision and equilibrium caused by a direct blow to the head, rapid acceleration and/or deceleration of the head, or direct blow to the base of the skull from a vertical impact to the chin. Concussions result in complications including severe headaches, dizziness, earaches, facial pain, ringing in the ears, nausea, irritability, confusion, disorientation, dizziness, amnesia, concentration difficulty, blurred vision, sleep disturbance, increased size of one pupil, severe weakness in an arm or leg, photophobia, vertigo, impaired speech and permanent brain damage.
[0004] A MTBI is also a traumatically induced alteration in brain function that is manifested by an alteration of awareness or consciousness, including, but not limited to, loss of consciousness, “ding,” sensation of being dazed or stunned, sensation of “wooziness” or “fogginess,” seizure, or amnesic period; and signs and symptoms commonly associated with post-concussion syndrome.
[0005] The CDC estimates that approximately one-third, i.e. 1.2 million, of the concussions and mild traumatic brain injuries (hereinafter “sports-related traumatic brain injuries”), which are “diagnosed” annually, occur playing football. Approximately 63,000 of the sports-related traumatic brain injuries occur annually among high school varsity athletes, with football accounting for about 63% of the cases. Sports-related traumatic brain injuries in hockey affect 10% of the athletes and make up 12%-14% of all injuries.
[0006] For example, a typical range of 4-6 sports-related traumatic brain injuries per year in a football team of 90 players (7%), and 6 per year from a hockey team with 28 players (21%) is not uncommon. In rugby, a sports-related traumatic brain injury can affect as many as 40% of players on a team each year.
[0007] As indicated, nearly 1.2 million sports-related traumatic brain injuries that are diagnosed annually occur playing football. Since many sports-related traumatic brain injuries go undetected, it is, however, believed that over 2 million football players suffer at least one sports-related traumatic brain injury each season.
[0008] Undetected sports-related traumatic brain injuries result from several factors. First, many athletes, particularly, professional athletes, often attempt to “shake it off” when they are hurt to maintain their playing status.
[0009] Second, over one-half (½) of high school football teams do not have access to a certified athletic trainer to assess on-field head injuries and/or determine when a player is attempting to mask symptoms of a sports-related traumatic brain injury.
[0010] Third, coaches and athletic trainers often do not have access to appropriate tools to monitor, track and/or quantify potentially harmful impacts.
[0011] As a result, it is estimated that nearly 80% of sports-related traumatic brain injuries that occur playing football go undetected.
[0012] It is also estimated that one-half (½) or more of the sports-related traumatic brain injuries are the result of blows proximate the lower jaw. Indeed, the CDC estimates that approximately 75% of the sports-related traumatic brain injuries that occur while playing football are the result of the lower jaw relaying the shock of impact to the brain.
[0013] Considerable research has thus been directed to developing means for dissipating the impact forces applied to the jaw. In 1964, seminal research by Stenger, et. al. indicated that forces from temporomandibular impact could be attenuated with a mouth guard (see Stenger, et al., Mouth guards: Protection Against Shock to the Head, Neck and Teeth , J. Am Dent Assoc, vol. 69, pp. 273-81 (1964)).
[0014] Various mouth guard designs have thus been developed to dissipate impact forces and/or shocks to the jaw. Illustrative are the custom mouth guards disclosed in U.S. Pat. Nos. 5,931,164, 3,532,091, 4,672,959, and 5,339,832.
[0015] U.S. Pat. No. 5,931,164 (Kiely, et al.) discloses an athletic mouth guard including a U-shaped base portion, an upwardly projecting inner flange portion joined to an inner edge of the base portion and an upwardly projecting outer flange portion joined to an outer edge of the base portion. The Kiely, et al. mouth guard is molded from a composition including a light pervious foundation material and a light reflective aggregate distributed throughout the foundation material.
[0016] U.S. Pat. No. 3,532,091 (Lerman) discloses a mouth guard that includes a relatively large closed passage-providing portion containing a fluid, either a liquid or a gas. The passage-providing portion is disposed either adjacent the labial surface of the teeth, between the occlusal surfaces of the upper and lower teeth, or in both positions. The closed fluid passage hydrostatically distributes forces exerted at one point thereon over a much greater area, thereby decreasing the detrimental effect of the blow.
[0017] U.S. Pat. No. 4,672,959 (May, et al.) discloses a mouth guard that includes a lens-like brace integrally formed in the outer upstanding portion of the elongated shell and positioned on the outer surface of the anterior teeth. The May mouthpiece further includes a thickened connecting portion overlying the biting surface of the posterior teeth to help prevent concussion and to lessen the shock to the tempro mandibular joint in the event of a blow to either the jaw or head.
[0018] Indentations are also formed in the thickened connecting portion opposite to the biting surfaces of the user's upper teeth. The indentations have a size and shape complementary to and for receiving the user's lower teeth to form an occlusal index for positioning the user's lower teeth, helping to eliminate the trauma of a blow to the side of the jaw.
[0019] U.S. Pat. No. 5,339,832 (Kittelsen, et al.) discloses a composite mouth guard having a tough, softenable thermoplastic mouth guard portion with a U-shaped base having upwardly extending inner lingual and outer labial walls. A shock absorbing and attenuating non-softening, resilient, low compression, elastomer framework is embedded in the mouth guard portion to absorb, attenuate and dissipate shock forces exerted on the mouth guard.
[0020] The Kittelsen, et al. framework also includes posterior cushion pads within the posterior portions of a U-shaped base with enlarged portions in the bicuspid and molar regions of the teeth to fit on the bicuspid teeth adjacent the canine teeth and in the area of the first adult molars, respectively. The cushion pads and enlarged portions, inter alia, prohibit the user from biting too deeply into the soft thermoplastic ethylene vinyl acetate (EVA) of the mouth guard portion and to ensure that there is no excessive upward displacement of the anterior portions of the lower mandible.
[0021] A transition support portion extends forwardly from the posterior cushion pads and connects to an anterior impact brace. The anterior impact brace has rearwardly protruding anterior cushion pads extending through the upward outer labial wall and contact the anterior teeth of the upper jaw to attenuate and dissipate shock exerted thereto.
[0022] The noted mouth guards are not your typical “boil and bite” guards and, hence, can, and in many instances will, cost in the range of $200-$500.
[0023] More recently, sensored mouth guards have also been developed to monitor impact forces and accelerations resulting from blows proximate the jaw. The sensored mouth guards are also quite expensive; typically costing in the range of $1500-$2500.
[0024] Although the incidences of sports-related traumatic brain injuries can be substantially reduced by using a mouth guard, the ability of a mouth guard to do so is primarily dependent upon the mouth guard properly aligning the jaw of the athlete. Similarly, sensored mouth guards must also be properly aligned to accurately monitor impact forces and accelerations.
[0025] Since many of the available mouth guards, including the aforementioned mouth guards, do not include tethers or other fastening means to retain (or store) the mouth guard, many athletes wedge the mouth guard snugly between the bars of the facemask or simply hold the mouth guard with their teeth. Such actions can, and in many instances will, deform the mouth guard, resulting in misalignment of the mouth guard and, hence, jaw when re-inserted in the mouth.
[0026] It would thus be desirable to provide apparatus, systems and methods for safely securing mouth guards to a variety of helmets that maintains the integrity of the mouth guard.
[0027] It is therefore an object of the present invention to provide mouth guard retention means and associated methods for securing mouth guards during non-use to a variety of helmets that maintain the integrity of the mouth guards.
[0028] It is another object of the present invention to provide mouth guard retention means and associated methods that facilitate quick and easy placement, retention and removal of mouth guards.
SUMMARY OF THE INVENTION
[0029] The present invention is directed to mouth guard retention apparatus, systems and methods for securing mouth guards (during non-use) to an athlete's helmet that maintains the integrity of the mouth guard. In a preferred embodiment of the invention, the mouth guard retention apparatus comprise an elastic retention member that is configured to be attached to a helmet and exert a predetermined engagement force to a mouth guard (when retained thereby) that securely retains the mouth guard against the helmet without deforming the mouth guard.
[0030] In a preferred embodiment of the invention, the maximum engagement force provided by the retention apparatus of the invention is less than approximately 1.0 lbs.
[0031] In some embodiments, the engagement force is preferably less than approximately 0.5 lbs.
[0032] In some embodiments, the engagement force is preferably in the range of approximately 0.25-0.5 lbs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] Further features and advantages will become apparent from the following and more particular description of the preferred embodiments of the invention, as illustrated in the accompanying drawings, and in which like referenced characters generally refer to the same parts or elements throughout the views, and in which:
[0034] FIGS. 1 and 2 are perspective views of a prior art mouth guard;
[0035] FIG. 3 is an illustration of a human skull and jaw showing the distribution of a force applied to the jaw;
[0036] FIG. 4 is a front plan view of a football helmet with a mouth guard wedged between bars of the facemask;
[0037] FIG. 5 is a perspective view of one embodiment of a mouth guard retention apparatus, in accordance with the invention;
[0038] FIG. 6 is a side plan view of the mouth guard retention apparatus shown in FIG. 5 , in accordance with the invention;
[0039] FIG. 7 is an illustration of a mouth guard retention apparatus of the invention showing the engagement (or recovery) force applied to a mouth guard secured thereby, in accordance with the invention;
[0040] FIG. 8 is a graphical illustration of exemplar mouth guard retention apparatus force profiles, in accordance with the invention;
[0041] FIG. 9 is a side plan view of another embodiment of a mouth guard retention apparatus, in accordance with the invention;
[0042] FIG. 10 is a top plan view of another embodiment of a mouth guard retention apparatus, in accordance with the invention;
[0043] FIG. 11 is a side plan view of the mouth guard retention apparatus shown in FIG. 10 , in accordance with the invention;
[0044] FIG. 12 is a front plan view of a football helmet with one embodiment of a mouth guard retention apparatus engaged on a front surface of the helmet, in accordance with the invention;
[0045] FIGS. 13 and 14 are side plan views a football helmet with the mouth guard retention apparatus shown in FIG. 12 engaged to the side of the helmet, in accordance with the invention; and
[0046] FIG. 15 is another front plan view of a football helmet with one embodiment of a mouth guard retention apparatus engaged on the lower facemask bars of the helmet, in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0047] Before describing the present invention in detail, it is to be understood that this invention is not limited to particularly exemplified apparatus, systems, structures or methods as such may, of course, vary. Thus, although a number of apparatus, systems and methods similar or equivalent to those described herein can be used in the practice of the present invention, the preferred apparatus, systems, structures and methods are described herein.
[0048] It is also to be understood that, although the mouth guard retention structures and systems of the invention are illustrated and described in connection with a conventional football helmet, the mouth guard retention structures and systems of the invention are not limited to a football helmet. According to the invention, the mouth guard retention structures and systems of the invention can be employed on any helmet, including, without limitation, a hockey helmet, skateboard helmet, auto racing helmet, etc.
[0049] It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments of the invention only and is not intended to be limiting.
[0050] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one having ordinary skill in the art to which the invention pertains.
[0051] Further, all publications, patents and patent applications cited herein, whether supra or infra, are hereby incorporated by reference in their entirety.
[0052] Finally, as used in this specification and the appended claims, the singular forms “a, “an” and “the” include plural referents unless the content clearly dictates otherwise.
Definitions
[0053] The terms “elastic” and “resilient” are used interchangeably herein, and mean and include a material that is capable of elongation of at least 20% in one direction without tearing.
[0054] The terms “engagement force” and “recovery force” are used interchangeably herein, and mean the force(s) applied to a mouth guard disposed between a mouth guard retention apparatus and a surface of a helmet when the apparatus is operatively engaged to the helmet.
[0055] The following disclosure is provided to further explain in an enabling fashion the best modes of performing one or more embodiments of the present invention. The disclosure is further offered to enhance an understanding and appreciation for the inventive principles and advantages thereof, rather than to limit in any manner the invention. The invention is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued.
[0056] As indicated above, the present disclosure is directed to mouth guard retention apparatus, systems and methods for securing (or storing) mouth guards to an athlete's helmet during non-use that maintains the integrity of the mouth guard. In a preferred embodiment of the invention, the mouth guard retention apparatus include an elastic retention member that is configured to be attached to a helmet and exert a predetermined engagement force to a mouth guard (when retained thereby) that securely retains the mouth guard against the helmet without deforming the mouth guard.
[0057] As indicated above, although the incidences of sports-related traumatic brain injuries can be substantially reduced by using a mouth guard, the ability of a mouth guard to do so is primarily dependent upon the mouth guard properly aligning the jaw of the athlete. Similarly, censored mouth guards must also be properly aligned to accurately monitor impact forces and accelerations.
[0058] As also indicated above, use of a mouth guard will, in most instances, dissipate impact forces applied or exerted proximate the jaw and reduce the incidences of concussions and mild traumatic brain injuries resulting therefrom. Illustrative is the mouth guard 10 shown in FIGS. 1 and 2 .
[0059] Referring now to FIG. 3 , when the jaw 100 is subjected to an impact or blow (denoted by arrow F 1 ), the force(s) resulting therefrom force the mandible 102 upward. The force(s) are then transferred from the end of the mandible, i.e. condyle 104 , to the base of the skull 110 , i.e. skull socket 112 (denoted by arrow F 2 ).
[0060] When the jaw 100 is subjected to a significant impact; particularly, without the use of a mouth guard, the condyle 104 can, and in most instances will, strike the base of the skull 110 with sufficient force to cause a traumatic brain injury. However, as stated, a properly aligned mouth guard, such as shown in FIG. 3 , can and will, in most instances, dissipate the impact force and prevent a traumatic brain injury.
[0061] As also indicated above, many of the available mouth guards, such as mouth guard 10 , do not include tethers or other fastening means to retain (or store) the mouth guard when not in use. As a result, many athletes using a helmet 20 wedge the mouth guard 10 snugly between the bars 24 of the facemask 22 during non-use, as shown in FIG. 4
[0062] Some athletes simply hold and often times chew the mouth guard 10 with their teeth.
[0063] Such actions can, and in many instances will, deform the mouth guard 10 , resulting in misalignment of the mouth guard 10 and, hence, jaw when re-inserted in the mouth.
[0064] Referring now to FIGS. 5-6 , there is shown one embodiment of a mouth guard retention apparatus of the invention. As illustrated in FIG. 5 , the retention apparatus 30 has a generally elongated, rectangular shape having top 32 and bottom 34 surfaces.
[0065] Disposed proximate each end 35 a, 35 b of the retention apparatus 30 are lumens 37 a, 37 b that are adapted to receive engagement screws therein to connect the apparatus 30 to a helmet (see FIGS. 12 and 13 ). Thus, in some embodiments of the invention, the retention apparatus lumens 37 a, 37 b are spaced a distance equal to the distance between pre-existing helmet facemask holes or screws, whereby the retention apparatus 30 can be attached at pre-existing helmet facemask holes, and, preferably with pre-existing helmet screws.
[0066] In a preferred embodiment of the invention, the retention apparatus 30 comprises a resilient of elastic elongated member. According to the invention, the retention apparatus 30 can thus comprise various resilient materials, including, without limitation, natural rubber and stretch polyvinyl chloride (or Vinyl™). In a preferred embodiment, the retention apparatus 30 comprises natural rubber.
[0067] In some embodiments of the invention, the natural rubber is impregnated or coated with a UV stabilizer to reduce environmental degradation of the rubber.
[0068] As indicated, in a preferred embodiment, when a retention apparatus of the invention (or a retention member thereof) is secured on both ends, i.e. engaged to a helmet, the retention apparatus provides a predetermined, controlled engagement force to a mouth guard when secured thereby.
[0069] Referring now to FIG. 7 , there is shown an illustration of retention apparatus 30 secured to a helmet 20 on both ends 35 a, 35 b, and stretched in a direction denoted by arrow E, whereby the apparatus 30 applies an engagement or recovery force in the direction of arrow F, which would be applied to a mouth guard that is positioned between the apparatus 30 and helmet 20 .
[0070] In a preferred embodiment of the invention, the retention apparatus of the invention provide an engagement force having a controlled force distribution, i.e. force profile, across the length of the apparatus (or member), with the maximum force, F m , being disposed proximate the center of the apparatus.
[0071] Referring now to FIG. 8 , there are shown exemplar predetermined engagement force profiles, i.e. F P1 , F P2 , F P3 , that can be provided via the retention apparatus of the invention. As illustrated in FIG. 8 (and stated above), the maximum engagement force, F m , is disposed proximate the mid-point of the apparatus length.
[0072] According to the invention, various means can be employed to provide the controlled force distribution, i.e. force profile, across the length of the apparatus (or member) and maximum engagement force, F m .
[0073] In some embodiments of the invention, the controlled engagement force is provided as a function of the material employed to construct the retention apparatus, i.e. modulus of elasticity, and the cross sectional area of the retention apparatus.
[0074] In some embodiments of the invention, the controlled engagement force is provided solely as a function of the cross sectional area of the retention apparatus. By way of example, referring back to FIG. 6 , in some embodiments, the retention apparatus ends 35 a, 35 b have a greater thickness than the central region 35 c of the apparatus 30 . According to the invention, the noted embodiment would provide a controlled, variable force profile to a mouth guard (when secured thereby) that is similar to force profile F P1 shown in FIG. 8 , i.e. the maximum force applied to the mouth guard being proximate the center of the retention apparatus.
[0075] Referring now to FIG. 9 , there is shown another embodiment of a retention apparatus 31 , wherein the bottom surface 34 of the retention apparatus 31 has a curvilinear shape. According to the invention, retention apparatus 31 would provide a controlled variable force profile to a mouth guard (when secured thereby), that is similar to force profile F P2 shown in FIG. 8 .
[0076] Referring now to FIGS. 10 and 11 , in some embodiments, the width across the top surface 32 of the retention apparatus 33 is greater proximate the ends 35 a, 35 b. According to the invention, the ends 35 a, 35 b can thus comprises various configurations, such as rectangular or circular, as shown in FIG. 10 .
[0077] In a preferred embodiment of the invention, the maximum engagement force, F m , provided by the retention apparatus of the invention is less than approximately 1.0 lbs.
[0078] In some embodiments, the maximum engagement force, F m , is preferably less than approximately 0.5 lbs. In some embodiments, the maximum engagement force, F m , is preferably in the range of approximately 0.25-0.5 lbs.
[0079] Referring now to FIG. 12 , there is shown one embodiment of a retention apparatus of the invention attached to a helmet 20 . As illustrated in FIG. 20 , the retention apparatus 30 is secured to the front of the helmet 20 ; preferably, above the facemask 22 , via existing helmet screws 26 a, 26 b to temporarily secure a mouth guard 10 between the retention apparatus 30 and helmet 20 .
[0080] According to the invention, the retention apparatus 30 can also be secured proximate the side 21 of the helmet 20 via existing helmet screws 26 c, 26 d, as shown in FIGS. 13 and 14 .
[0081] Referring now to FIG. 15 , in some embodiments of the invention, the mouth guard retention apparatus 34 has an extended length that is sufficient to wrap around a bar 24 of the facemask 22 and directly engage a facemask retainer 28 . In the noted embodiments, the mouth guard 30 can simply be placed within the looped apparatus 34 .
[0082] With reference to FIGS. 12 , 13 and 15 , when an athlete temporarily removes a mouth guard from his/her mouth, e.g. during a huddle or on the side lines, the athlete can place the mouth guard in a secured mouth guard retention apparatus of the invention (whether positioned on the front or side of the helmet). Since mouth guards are generally U-shaped, by placing one end of the mouth guard in a mouth guard retention apparatus of the invention, as shown in FIGS. 12 , 13 and 14 , one end of the mouth guard will be easily accessible for removal and use.
[0083] As will readily be appreciated by one having ordinary skill in the art, the present invention provides numerous advantages compared to prior art methods and systems for temporarily holding mouth guards when not in use. Among the advantages are the following:
The provision of mouth guard retention means and associated methods for securing mouth guards to a variety of helmets that maintain the integrity of the mouth guards. The provision of mouth guard retention means and associated methods that facilitate quick and easy placement, retention and removal of mouth guards.
[0086] Without departing from the spirit and scope of this invention, one of ordinary skill can make various changes and modifications to the invention to adapt it to various usages and conditions. As such, these changes and modifications are properly, equitably, and intended to be, within the full range of equivalence of the following claims. | A mouth guard retention apparatus comprising an elongated elastic retention member configured to be attached to an exterior surface of a helmet, whereby a mouth guard retention space is defined thereby, the elastic retention member being further configured to apply a predetermined engagement force to a mouth guard when disposed in the mouth guard retention space that securely retains said mouth guard against the helmet during temporary periods of non-use without permanently deforming said mouth guard. | 0 |
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 14/174,700, filed on Feb. 6, 2014, which claims the benefit of U.S. Provisional Patent Application, Ser. No. 61/835,188 filed on Jun. 14, 2013 and U.S. Provisional Patent Application, Ser. No. 61/886,509 filed on Oct. 3, 2013, each incorporated herein by reference in its entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates to downhole radiation measurement assemblies.
[0004] 2. Description of the Related Art
[0005] Downhole radiation measurement assemblies have been used in drilling operations for some time. In downhole drilling it is useful identify sub-surface rock formations and customize drilling assemblies and drilling methods to suit a particular geological formation. This can be useful when, for example, a drilling rig has been configured to be effective for a particular type of rock formation and characteristics of the rock formation change as the wellbore extends deeper beneath the surface. It would thus be useful to identify rock formations present at various drilling depths at a wellsite. Downhole radiation measurement assemblies measure the naturally occurring low level radiation that is given off by rock formations downhole. Different types of rock can give off differing amounts of radiation or radiation having other differing characteristics and if measured accurately, the type of rock formations at different depths can be identified. Often, radiation measurement assemblies are deployed downhole and many measurements are taken at different depths in a well. The sensor measurements can then be communicated uphole and processed to determine the particular types of rock formations present at various depths at a particular wellsite. Radiation measurement assemblies can experience harsh vibrations and temperatures as well as other environmental conditions during the installation process, when taking radiation measurements, while sitting downhole, and also during retrieval. Over time drilling operations have seen drilling to greater depths, causing radiation measurement assemblies to experience increasingly harsher environments. In addition, many of the radiation measurement sensors can be particularly sensitive and malfunction in response to vibration, harsh temperatures, and other environmental factors. Vibration factors can be particularly problematic for radiation measurement sensors used in downhole radiation measurement assemblies. This can be due in part to the construction and sensitive components of radiation measurement assemblies. These factors and others continue to create the need for more advanced and reliable downhole radiation measurement assemblies.
[0006] Radiation measurement assemblies are commonly deployed with measurement while drilling tools. The purpose of measurement while drilling tools is to collect various sensor based measurements and facilitate the communication of the measurements to the surface. Measurement while drilling tools can be deployed with sensors for measuring various downhole conditions such as temperature, flow data, drillstring rotation, location information, radiation readings, or other useful downhole conditions. The sensors deployed alongside or as a part of measurement while drilling tools will often be configured to communicate data with the microcontroller or microprocessor that is a part of the measurement while drilling tool assembly deployed downhole. This communication may be made using standard protocols that transmit over bus connections between the measurement while drilling tool and the various sensors. Measurement while drilling tools can then communicate data from the sensors uphole to remote computers or data logging equipment. Measurement while drilling tools can be deployed by wireline or inline with the drillstring and can include remote power supplies or receive power over cabling run downhole. It is common to deploy a radiation probe that is connected to a measurement while drilling tool downhole to perform radiation measurements at various depths. The measurement while drilling tool can be configured to receive gamma probe data, which for example may be in the form of a pulse train, and then process and communicate the data to remote computers on the surface.
[0007] It would be desirable to have radiation measurement assemblies that include greater resilience to vibration, harsh temperatures, and other environmental factors that are present downhole. Further, it would be desirable to provide increased meantime between failures of radiation measurement assemblies installed downhole. This would allow greater drilling time, increased measurement time, and decreased time spent installing, retrieving, and servicing radiation measurement assemblies. It would further be desirable to decrease the time committed to servicing radiation measurement assemblies due to the failures of radiation measurement sensors that are particularly sensitive to the harsh environments downhole.
SUMMARY OF THE INVENTION
[0008] The present invention provides an improved gamma controller assembly to facilitate reliable measurement of naturally occurring radiation emitted from geological formations downhole. Radiation measurements are taken by multiple gamma sensors that are part of the improved gamma controller assembly. When the gamma sensors detect radiation they transmit pulses to a microcontroller that interprets and checks the measurements and then sends them uphole. In an alternate embodiment the microcontroller also writes the measurements to memory downhole. Once sent uphole, the measurements can be further processed and communicated to determine and display the make-up of geological formations downhole. The gamma controller assembly includes multiple gamma sensors, one or more microcontrollers, memory for storing the program run by the gamma controller assembly and for logging gamma sensor data, and input/output ports among other components. Gamma sensor data from multiple gamma sensors can be selected or averaged by the microcontroller and stored to memory or stored as independently logged values to memory. The sensor data can then be sent uphole to another microcontroller or computer based system that can then further process, communicate, and display the data. The gamma controller assembly is configured to run algorithms that detect if one gamma controller appears to be malfunctioning, and if the apparent malfunction has occurred, the assembly can be configured to communicate only the data from the correctly functioning sensors uphole. In another embodiment the gamma controller assembly can send all sensor data uphole and communicate what data is trusted and what data is not trusted. Once uphole, the gamma sensor data can then be further communicated to another microcontroller or computer based system for additional evaluation, processing, storage, or display.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Various aspects and attendant advantages of one or more exemplary embodiments and modifications thereto will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0010] FIG. 1 depicts a block diagram of a multiple gamma controller assembly.
[0011] FIG. 2 depicts a schematic representation of the multiple gamma controller assembly.
[0012] FIG. 3 depicts a schematic representation of the multiple gamma controller assembly.
[0013] FIG. 4 depicts a side view of the multiple gamma controller assembly.
[0014] FIG. 5 depicts a side perspective view of the multiple gamma controller assembly.
[0015] FIG. 6 depicts a side view of the multiple gamma controller assembly.
[0016] FIG. 7 depicts a side perspective view of the multiple gamma controller assembly within a well bore.
[0017] FIG. 8 depicts a side perspective view of a multiple gamma controller assembly chassis.
[0018] FIG. 9 depicts a side perspective view of a multiple gamma controller assembly circuit board.
[0019] FIG. 10 depicts a side perspective view of a cross-over member of the multiple gamma controller assembly.
[0020] FIG. 11 depicts a block diagram of a measurement while drilling tool having only a single gamma sensor.
[0021] FIG. 12 depicts a block diagram of a measurement while drilling tool having the multiple gamma controller assembly.
[0022] FIG. 13A depicts a first portion of a flow chart of a kick-out algorithm for the multiple gamma controller assembly, with FIG. 13B depicting a second portion.
[0023] FIG. 13B depicts the second portion of a flow chart of a kick-out algorithm for the multiple gamma controller assembly, with FIG. 13A depicting the first portion.
DETAILED DESCRIPTION
[0024] One purpose of the improved gamma controller assembly is to increase the reliability of downhole gamma sensor measurements. One of the frequent failures in a measurement while drilling system is for the gamma probe to fail. This can be very costly to remedy as the entire drill string has to be pulled from the well to replace the gamma probe, if there is even a spare available.
[0025] To mitigate this failure mode, the multiple gamma controller assembly facilitates redundant gamma probes in a single measurement while drilling tool. The multiple gamma controller assembly can also be configured to log various parameters of the tool downhole to assist with failure analysis when the tool is serviced. Using heuristics, if the multiple gamma controller assembly determines that each gamma probe is operating correctly, the multiple gamma controller assembly can then output a single pulse train which is a combined and filtered or alternately a single averaged reading from the multiple individual gamma probes to the measurement while drilling tool. In an alternate embodiment, the combined, filtered, or averaged reading output by the multiple gamma controller assembly can be communicated over a CAN bus or other bus known in the industry, to either the measurement while drilling tool or to other equipment uphole via mud pulsers, signal lines, or other communication methods. If however the multiple gamma controller assemblies' heuristics determine that one of the gamma probes has failed, it can exclude the failed gamma probe from the filtered output and only output a filtered pulse train based on the readings from the remaining gamma probes. In the preferred embodiment, it is preferred that two gamma sensor probes would be configured in each multiple gamma controller assembly; however, it is equally possible that three or more probes could be configured in a single assembly. For this embodiment the multiple gamma controller assembly may also be referred to as a dual gamma controller assembly. The mode in which a single pulse train is output to the measurement while drilling tool in particular is designed to work with measurement while drilling systems that expect to see one pulse train from a single gamma sensor downhole. In an alternate embodiment, data from each gamma sensor can be communicated to a measurement while drilling tool or uphole with an indicator as to what sensor data is trusted and what sensor data may be incorrect due to a possibly malfunctioning gamma probe.
[0026] Referring to FIGS. 1 , 2 , and 3 , the multiple gamma controller assembly 10 has a controller module 18 that can be configured to include one or more microcontrollers or processors 20 ; one or more power supplies 30 ; memory 40 for storing the main executable program, for logging, and for storing configuration parameters; and accelerometers 50 or similar sensors for sensing shock and vibration. The multiple gamma controller assembly 10 further includes multiple gamma probes 60 a and 60 b , though more than two probes can be configured in an alternate embodiment. The controller module 18 can be configured to provide power to the gamma probes 60 a and 60 b over gamma probe power lines 62 a and 62 b . Data lines 64 a and 64 b also extend between the controller module 18 and the gamma probes 60 a and 60 b . In addition, the multiple gamma controller assembly 10 can be configured to include power lines 70 , serial communication lines 72 , and gamma sensor pulse output lines 74 that extend to a measurement while drilling tool (not shown) or from lines running from the surface to the tool. A single memory element can be shared for the main executable program, logging, and storing configuration parameters, or multiple memory elements can be utilized. There are three primary functions of the microcontroller or processor 20 : (1) monitoring the health of the gamma probes, (2) logging tool parameters for failure analysis, and (3) sending gamma probe measurement data to a measurement while drilling tool or directly uphole. The multiple gamma controller assembly 10 can have multiple modes of operation, which are not mutually exclusive. In an embodiment the multiple gamma controller assembly 10 can have a transparent mode, where the controller will simply output a combined, filtered, or averaged pulse train to a measurement while drilling tool (not shown), and thus appearing to the measurement while drilling tool as a single gamma probe. This approach provides additional accuracy and reliability to current systems that are only configured to interact with a single gamma probe. In this mode, the measurement while drilling systems are “tricked” into thinking they are only receiving output from a single probe. In fact, this approach provides increased accuracy and reliability for low bandwidth systems that could not provide enough bandwidth to transmit data from multiple gamma sensors uphole. An alternate mode of operation allows the multiple gamma controller assembly to transmit data from the gamma probes and overall tool health status to the measurement while drilling unit as generic data values over the serial bus inside the tool, or over other bus types. For many types of measurement while drilling tools, this bus can have limited bandwidth, but for higher bandwidth systems, more sensor data could be communicated using this mode. Finally, if higher bandwidth systems are used, another alternate embodiment can allow for sensor data from each gamma probe sensor to be sent to the measurement while drilling tool or even uphole as separate pulse trains or by other means that would allow all of the sensor data or data from a select multiple number of sensors to be sent uphole.
[0027] Referring to FIG. 4 , a multiple gamma stack assembly 100 is shown. The multiple gamma stack assembly 100 includes a multiple gamma controller chassis 110 that includes a controller circuit board module 120 ; a first gamma module 130 ; a second gamma module 140 ; a bus-cross-over module 150 , and a snubbing end 160 . Referring to FIG. 5 , the multiple gamma controller chassis 110 houses the controller circuit board module 120 that is analogous to controller module 18 referenced in FIGS. 1-3 . Module 120 can be configured to include one or more microcontrollers or processors; one or more power supplies or power supply voltage regulators; memory for storing the main executable program, for logging, and for storing configuration parameters; and accelerometers or similar sensors for sensing shock and vibration. In an embodiment, each of these sub-components may alternately be configured on separate circuit boards or as a part of other modules within the system. The chassis 110 provides sturdy connection ports 112 for connecting electrical lines between modules. A top hatch 114 and bottom hatch 116 protect the controller circuit board module 120 from the harsh downhole environments and also allow easy access for servicing. In alternate embodiments, different protective enclosures can be configured to protect the controller circuit board module 120 and the various other components of the multiple gamma stack assembly 100 .
[0028] Referring to FIG. 6 , a multiple gamma stack assembly 100 is shown connected to a battery unit 200 and a pulser driver 300 . The pulser driver 300 is one example of a communication system that can be configured to send information uphole or to the surface and receive information downhole from the surface. The pulser driver 300 can be configured to send and receive pulses through the drilling mud that can be detected by sensors. The pulses can then be interpreted by the sensors or other connected equipment. When deployed downhole this configuration or similar configurations may be used, for example non-pulser based communications systems such as wire based systems may also be used to send information and communicate with surface equipment. Referring to FIG. 7 , an alternate perspective view of the multiple gamma stack assembly 100 is shown. Referring to FIG. 8 , the gamma controller chassis 110 is shown with the top hatch 114 connected to the bottom hatch 116 , both of which serve to protect the controller circuit board module 120 from harm. FIG. 9 shows a side perspective view of the controller circuit board module 120 that, as described above, can be configured to include various components of the multiple gamma controller assembly.
[0029] Referring to FIG. 10 the bus cross-over module 150 is shown. For multiple gamma controller assemblies that include three or more gamma probes, multiple bus cross-over modules 150 can be configured to allow the connection of additional probes. In an embodiment, the bus cross-over module 150 facilitates the connection of multiple gamma probes to a multiple gamma controller in a system that was originally designed for the use with only a single gamma probe. The cross-over module 150 can be configured to place gamma probe output line data onto spare signal carrying lines of the bus, the multiple gamma controller can then read and interpret the output of the gamma probes in these lines. FIG. 11 is an example block diagram showing the components and wiring layout of a measurement while drilling tool 400 having a single gamma probe 410 . In this example a pulser driver 420 serves as the surface communication link to the tool 400 and battery power is provided to the various components through battery one 430 and battery two 440 . A main processing unit (“MPU”) 450 , triple power supply (“TPS”) 460 , and orientation module (“OM”) 470 are also included in this configuration. The gamma probe 410 output radiation measurement readings on the gamma bus line 480 . The readings are then processed by the MPU 450 which then sends representative data values or the full pulse train information to the surface through the pulser drive 420 . In addition to the gamma bus line 480 , the bus 405 that runs between the various components can include a ground line (“GND”) 490 , a battery one line (“Batt1”) 491 , a battery two line (“Batt2”) 492 , a BBus signal line (“BBus”) 493 , a qBus signal line (“qBus”) 494 , a pulse signal line (“Pulse”) 495 , a flow signal line (“Flow”) 496 , an m1 signal line (“M1”) 497 , and an m2 signal line (“M2”) 498 . The bus described carries power from the batteries to the various components and also serves as the communication links between the components.
[0030] Referring to FIG. 12 , an example block diagram showing the components and wiring layout of a measurement while drilling tool 500 having multiple gamma probes and a multiple gamma controller 514 is shown. Gamma probe 510 and gamma probe 512 output their radiation measurement readings to the multiple gamma controller 514 . The bus cross-over module as described in FIG. 10 can be configured when implementing this layout to, re-route the output of each gamma probe onto spare signal lines that are part of the bus. The gamma probe data is routed to the microcontroller of the multiple gamma controller assembly and the microcontroller runs algorithms against the gamma probe output data to determine the gamma probe data to place onto the gamma probe output line or lines that is then communicated to a measurement while drilling tool or other data channels that communicate the information uphole. Similar to the single probe configuration described in FIG. 11 , in this example a pulser driver 520 serves as the surface communication link for the tool 500 and battery power is provided to the various components through a battery one 530 and a battery two 540 , A main processing unit (“MPU”) 550 , triple power supply (“TPS”) 560 , and orientation module (“OM”) 570 can also be included in this configuration. The first gamma probe 510 outputs radiation measurement readings on the gamma output line 580 and the second gamma probe 512 outputs radiation measurement readings on the gamma output line 584 . The readings are then received and processed by the multiple gamma controller 514 , which combines, averages, or filters the readings using one or more of the methods described herein. The multiple gamma controller 513 then continuously generates a representative gamma output value that is sent to the MPU 550 or the pulser driver 520 for communication uphole. Similarly to the methods described above, heuristics can be employed by the multiple gamma controller 514 and probe data can be adjusted, disqualified, and re-qualified accordingly. In addition to the gamma bus line 580 , the bus that runs between the various components can include a ground line (“GND”) 590 , a battery one line (“Batt1”) 591 , a battery two line (“Batt2”) 592 , a BBus signal line (“BBus”) 593 , a qBus signal line (“qBus”) 594 , a pulse signal line (“Pulse”) 595 , a flow signal line (“Flow”) 596 , an m1 signal line (“M1”) 597 , and an m2 signal line (“M2”) 598 . The bus described carries power from the batteries to the various components and also serves as the communication links between the components. The bus described in this paragraph is merely one embodiment and configuration of the multiple gamma controller assembly. Other bus configurations, tool configurations, communication protocols, and communication topologies can be used in conjunction with the multiple gamma controller assembly. Using the methods described, a multiple gamma controller assembly can be integrated into a tool that typically only uses one gamma probe, such as the system described in reference to FIG. 11 . Bus cross-over modules can be configured for use in the described system to carry the gamma probe output data over spare bus signal lines or alternatively other signal lines apart from the main bus can be used. The multiple gamma controller assembly can also be integrated into other types of systems that are configured to only use one gamma probe by default.
[0031] In an embodiment, the multiple gamma controller assembly can be configured to interact with multiple measurement while drilling tools, different types of measurement while drilling tools, or other tools that allow communication to the surface. For each of these tools, different amounts of bandwidth may be available to transmit data uphole and the multiple gamma controller assembly can be configured to send more or less gamma sensor data depending on the bandwidth available. For example, the frequency of the readings sent to the surface can be adjusted according to the bandwidth available for the transmission.
[0032] Further, in an embodiment, the filtering of the output counts from the multiple gamma probes could simply be the average of the counts per second (or other time interval) from the multiple gamma probes. Additionally, the filtering could also be a weighted average of the gamma sensor outputs, if certain sensors are determined to be in better health than the others. More advanced filtering may also be performed using a state estimator to estimate the overall background radiation based on the readings from the multiple gamma probes. The filtered output can also take into account the API calibration factors for each gamma probe, and these values can be stored in the multiple gamma controller assembly's memory.
[0033] The microcontroller or processor of the multiple gamma controller assembly can continually monitors the pulse train output of each gamma probe which should correspond directly to the gamma radiation levels downhole. The microcontroller can be configured to keep statistics about the performance of each gamma probe, and if, based on its heuristics it determines that one of the gamma probes has failed, it will exclude from the combined, filtered, or averaged, output the counts of the failed probe.
[0034] Several different heuristics can be used to determine if a gamma probe is malfunctioning. In an embodiment, those heuristics may optionally include, but are not limited to: (1) high counts, that is counts greater than some threshold, (2) low counts, that is counts less than some threshold, (3) counts changing too quickly, meaning that the rate at which the counts are increasing or decreasing (the derivative of the counts per second with respect to time) is too high/low, (4) the standard deviation over time is increasing beyond an acceptable limit, (5) kurtosis analysis, (6) skew of counts over time, or (7) other statistical measurements. If a gamma probe is determined to be malfunctioning based on the heuristics, then, for a microcontroller operating in a single pulse train mode, the counts from the probe may no longer be included in the filtered output or pulse train of the microcontroller. Likewise, in a mode where multiple sensor outputs are being communicated to the measurement while drilling tool or uphole, when the heuristics detect the possible malfunction of a sensor, the output data for that sensor may be tagged as invalid or potentially incorrect. However, the outputs from the failed gamma probe will be continually monitored to determine whether or not the gamma probe has recovered. Occasionally gamma probes output unreasonably high counts as the temperature increases, or if a shock event occurs, but then recover once the temperature decreases or the shock/vibration levels decrease. If a failed gamma probe is determined to be within the operational limits once again for some set period of time, then it can once again be included in the filtered output or pulse train or the tagging included with the gamma probe data can be changed back to valid or good.
[0035] In an embodiment, the microcontroller can be configured to constantly compare the values read from both gamma probes and compare or check the health status data for each of the gamma probes as well. Generally, there are two main failure modes for the gamma probes, high counts and low counts. Either failure mode has to do with some portion of the standard gamma sensor failing. For example, the crystals can crack, the photomultiplier tubes can crack or otherwise fail, the high voltage power supply can drift or stop supplying power, and in some cases the discriminator circuit may fail as well. Typically these failures cause a gamma sensor to return no counts at all or abnormally high counts. Based on this notion the microcontroller of the multiple gamma controller assembly is configured to run algorithms that check for high and low counts. In an embodiment, a low and a high threshold are set in accordance with readings anticipated from gamma sensors downhole. These threshold values may be adjusted for different types or brands of sensors, or to accommodate for desired thresholds at a particular wellsite. If the readings from any one gamma sensor exceed these bounds, high or low, it is immediately disqualified from the system and any averaging calculation that is performed. In some of the alternate embodiments where gamma sensor readings from more than one gamma probe are conveyed, the data from an out of bounds probe is merely flagged as invalid or disqualified. To be considered operational again, the reading must return to the acceptable range and stay within bounds for a set timeframe. If the sensor stays out of bounds for a large amount of time, it can be permanently disqualified from the calculation, at least for a given installation or over a certain time period.
[0036] In an alternate embodiment where three or more gamma probes are configured, a majority rules protocol can be put into place. In this setup the two probes with the closest counts are used and can be combined, averaged, or filtered, with the readings from the third probe being discounted for a given reading comparison or for a given time period. In this configuration, should one or more probes fail, the remaining probes can be switched from the majority rules protocol back to other methods where all of the probes values are again combined, averaged, filtered, or otherwise processed and then communicated to the measurement while drilling tool or uphole.
[0037] Some probes can also be sensitive to temperature and have counts that drift at temperature extremes. Comparing temperature readings to count data can be used to determine if a particular probe is experiencing temperature drift and adjustment can be made to the count values from that probe. Alternatively, if a temperature drift passes a pre-determined threshold the probe can be disqualified temporarily and re-qualified later if readings return to within the pre-determined threshold.
[0038] Referring to FIGS. 13A and 13B , two portions of a single flowchart of an example algorithm 600 run by the multiple gamma controller is shown. In this example, the system starts 610 and one algorithm routinely checks and logs telemeter status 660 so that location information can be associated with the readings collected by the probes. The health of the telemeter status readings can optionally be checked as part of this sequence using heuristics based algorithms. Collected data may be disqualified or data logging may be suspended if telemeter readings are called into question. A routine algorithm is also run to evaluate gamma one 620 and evaluate gamma two 640 , and determine if the counts received are between pre-determined high and low values. The pre-determined values can be different for different probe types of for different individual probes of the same type, this may be based on testing, calibration values, or the previous use of a given probe. Additionally, the high and low values may be set to different ranges for different rock formations and other environmental conditions. The gamma probe readings are each evaluated to determine if they are in bounds 621 641 of the pre-determined range. If a value is determined to be in bounds 621 641 , a routine algorithm then checks to see if the gamma probe was recently flagged 630 650 . If the probe was flagged 630 650 , it is not considered in the average 631 651 but instead checked to be in bounds for a pre-determined time 632 652 , in this example, one minute. If the probe is in bounds for greater than one minute 632 652 , the flag disqualifying the probe is cleared 633 653 , and the next time the probe is checked and verified in bounds the readings from that probe will be considered in the average 631 651 . Alternatively, the probe readings may be considered in an average, combined, filtered, considered in a majority rules protocol comparison, or otherwise used as described in the various algorithms. As this is an example, in an alternate embodiment the probes can also be flagged and temporarily or permanently for various other reasons, consistent with what has been mentioned previously. When a probe is determined to be in bounds 621 641 and determined to be not flagged 630 650 , it may then be considered in average 631 651 or otherwise considered-good by the multiple gamma controller. A gamma probe that provides out of bounds data is flagged 622 642 the first time it provides an out of bound result. If the gamma probe continues to provide out of bounds results in excess of the configured ten minute timeframe 623 643 of this example, the probe is permanently disqualified from use 624 644 . In this event, the multiple gamma controller assembly can be configured to send a message to a remote computer indicating the probes failure (not shown). When a probe is permanently disqualified 624 644 , evaluation of the probes output is stopped 625 690 . In an embodiment, the described sequences can optionally be carried out on more than two probes. Also, in an embodiment, this sequence need not be carried out on all of the probes configured, some probes can optionally remain inactive in a particular system configuration. If all of the probes in a given system are no longer being evaluated a count of zero will be recorded 634 , indicating there may be a problem with the probes. As long as one probe remains operational and is returning readings, the tool can remain in use until a convenient service window opens, at which time the failing probes can be replaced.
[0039] More complex algorithms can be applied. For example, gamma sensors can be disqualified if one drifts apart from the other, or as well is they become too noisy and return values that are within bounds but erratic. All of the thresholds and disqualification parameters are configurable. In another embodiment, the multiple gamma controller assembly can be configured to exclude measurements or disqualify measurements based on the conditions at the time. For example, if a high shock (triboluminescence) event occurs, the assembly could suspend measurement or disqualify measurements for a given time period during or near the shock event. Other events may also suspend measurement, another example might be when other operations are being performed by the measurement while drilling tool or other downhole tools that could potentially give off electrical noise, the multiple gamma controller assembly can be notified before such an event occurs or be programmed with algorithms to detect such an event through sensor measurement or other methods. High temperature events can also receive similar treatment. The conditions which trigger these events are programmable and can vary based on the probes being used and their particular sensitivities.
[0040] To assist with failure analysis when the tool is being serviced, the multiple gamma controller assembly can log several relevant parameters of the gamma controller assembly or of other components of the tool as it is operating. There are at least two classifications of events that can be logged: time-based logs and event-based logs. Time-based logs can include parameters that are logged periodically regardless of what is happening with the tool. Examples of this include temperature, battery voltages, motor bus voltage, axial vibration, lateral vibration, moving average of the counts from each gamma probe, etc. Event-based logs can include specific events that may occur, including axial or lateral shock events, as monitored by the accelerometers or other similar sensors, changes in the state of the flow signal, changes in the state of the pulse line, the duration of a pulse event, etc.
[0041] In an embodiment, the multiple gamma controller can be configured with “high-g” and “low-g” accelerometers to measure shock and vibration measurements. Generally, shock is considered events above 25 G, and can be recorded along with other information, such as time, date, and other sensor values. Recording the number of shock events provides a good predictor of a particular type of drilling environment and allows the prediction of the remaining lifetime of the multiple gamma assembly for a certain number of gamma probes in that type of environment or at that particular wellsite. If a shock is recorded above a very high threshold, immediate replacement of the crystal and photomultiplier assembly can be considered as they may be very close to failure if not already malfunctioning. Messages can be sent by the microcontroller through the measurement while drilling tool interface or separately to the surface to alert operations personnel. The same considerations can be applied to vibration measurement by the “low-g” accelerometers. The multiple gamma assembly can be configured such that down-hole vibration levels can be continuously calculated and logged to memory. Additionally the multiple gamma assembly can also be configured with on-board temperature sensors and the complete temperature profile history may be tracked since high temperatures also place very high stress on the board. Thresholds may be set for temperature events and similarly to gamma failure, shock, or vibration events, messages can be sent to the surface through the measurement while drilling tool interface or through a separate interface to the surface.
[0042] In another embodiment, event “odometers” can be setup to tack the various tool health indicators, such as the various sensor values, as previously mentioned. The odometers may accumulate value as separate, shock, vibration, and temperature odometers, and provide an idea to the tool operators of the general abuse a particular tool has taken. This may be useful to determine and improve upon common modes of failure for a particular tool design. For example, it may be found that tools with a certain level on their vibration odometers are likely fail within a calculated timeframe based on tool data compiled over time. Vibration odometers can be configured to represent total time spent at vibration levels corresponding to bin divisions. Temperature odometers can be configured to represent total time spent at temperature levels corresponding to bin divisions. Odometers can optionally be reset when the multiple gamma controller assembly is paired with different gamma probes or when the multiple gamma controller circuit board is replaced.
[0043] In an embodiment, the multiple gamma controller assembly can be configured to apply individual calibrations for each gamma probe, optionally applying the calibrations before averaging or determination operations are performed. The averaged or calculated values can be transmitted to the measurement while drilling tool as synthesized voltage pulses as well as through the generic variable communication mean available, such as by a serial port communication to the measurement while drilling tool. The measurement while drilling tool is programmed with a calibration of 1.0 (multiplier) so as not to skew the data calculated by the multiple gamma controller assembly, for a given embodiment.
[0044] These logs allow the failures of the gamma probes to be analyzed and improve future operational guidelines to help prevent future failures of gamma probes downhole. Additionally, these logs allow predictive maintenance to be performed by preemptively replacing gamma probes that are likely to fail soon, before a downhole failure occurs. Gamma probes are generally constructed by pairing NaI(TI) (Sodium Iodide/Thalium) crystals with photomultiplier tubes. The probes also often have high voltage supply circuitry and a discriminator circuit integrated as well. Each component and the paired assembly have inherent structural weaknesses and can malfunction when exposed by the harsh conditions of a drilling environment. The gamma probe components are very temperature, vibration and shock sensitive, and often break irreparably in the drilling environment. In addition, the photo-multiplier has glass components, which are particularly sensitive to vibration and shock.
[0045] A gamma probe is configured to produce a pulse when a gamma wave/particle emitted from a geological formation comes into contact with the NaI(TI) crystal of the gamma probe. When collision occurs, a photon is produced. A hermetically sealed enclosure of the crystal is internally reflective, and will guide the photon out of one open end of the crystal, which is configured with a clear glass lens. The photon will travel out of the crystal, through the optical lens, and into a photomultiplier tube of the gamma probe. When the photon strikes a particular surface of the photomultiplier tube, an electrical current pulse is generated. The photomultiplier tube's purpose is to convert the photon into electrical energy so that it can be sent to and interpreted/read by the microcontroller circuitry of the multiple gamma controller assembly. A high voltage power supply is required to operate the photomultiplier tube. For example, photomultiplier tubes often require voltages around 1500V DC.
[0046] Although the concepts disclosed herein have been described in connection with the preferred form of practicing them and modifications thereto, those of ordinary skill in the art will understand that many other modifications can be made thereto. Accordingly, it is not intended that the scope of these concepts in any way be limited by the above description. | An improved gamma controller assembly to facilitate reliable downhole measurement of naturally occurring radiation is disclosed. The gamma controller assembly includes multiple gamma sensors, a micro-controller, memory, and input/output ports among other components. The multiple gamma sensors detect radiation and output pulses that are received by the microcontroller. The sensor data can be checked, selected, and averaged by the microcontroller, and sent uphole to another microcontroller or computer that can then further process, communicate, and display the data. The sensor data can be averaged and stored to memory or stored as independent values to memory. The gamma controller assembly can be configured to run algorithms that detect if one gamma controller appears to be malfunctioning and, if an apparent malfunction has occurred, adjust the sensor data that is being sent uphole. | 6 |
BACKGROUND
[0001] 1. Technical Field
[0002] Embodiments of the subject matter disclosed herein generally relate to methods and devices and, more particularly, to mechanisms and techniques for recharging a device that generates a subsea force.
[0003] 2. Discussion of the Background
[0004] During the past years, with the increase in price of fossil fuels, the interest in developing new production fields has dramatically increased. However, the availability of land-based production fields is limited. Thus, the industry has now extended drilling to offshore locations, which appear to hold a vast amount of fossil fuel.
[0005] The existing technologies for extracting the fossil fuel from offshore fields may use a system 10 as shown in FIG. 1 . More specifically, the system 10 may include a vessel 12 having a reel 14 that supplies power/communication cords 16 to a controller 18 . A Mux Reel may be used to transmit power and communication. Some systems have hose reels to transmit fluid under pressure or hard pipe (rigid conduit) to transmit the fluid under pressure or both. Other systems may have a hose with communication or lines (pilot) to supply and operate functions subsea. However, a common feature of these systems is their limited operation depth. The controller 18 is disposed undersea, close to or on the seabed 20 . In this respect, it is noted that the elements shown in FIG. 1 are not drawn to scale and no dimensions should be inferred from FIG. 1 .
[0006] FIG. 1 also shows a wellhead 22 of the subsea well 23 and a drill line 24 that enters the subsea well 23 . At the end of the drill line 24 there is a drill (not shown). Various mechanisms, also not shown, are employed to rotate the drill line 24 , and implicitly the drill, to extend the subsea well.
[0007] However, during normal drilling operation, unexpected events may occur that could damage the well and/or the equipment used for drilling. One such event is the uncontrolled flow of gas, oil or other well fluids from an underground formation into the well. Such event is sometimes referred to as a “kick” or a “blowout” and may occur when formation pressure exceeds the pressure of the column of drilling fluid. This event is unforeseeable and if no measures are taken to prevent it, the well and/or the associated equipment may be damaged.
[0008] Thus, a pressure controlling device, for example, a blowout preventer (BOP), might be installed on top of the well to seal the well in case that the integrity of the well is affected. The BOP is conventionally implemented as a valve to prevent the release of pressure either in the annular space between the casing and the drill pipe or in the open hole (i.e., hole with no drill pipe) during drilling or completion operations. FIG. 1 shows BOPs 26 or 28 that are controlled by the controller 18 , commonly known as a POD. The controller 18 controls an accumulator 30 to close or open BOPs 26 and 28 . More specifically, the controller 18 controls a system of valves (not shown) for opening and closing the BOPs. Hydraulic fluid, which is used to open and close the valves, is commonly pressurized by equipment on the surface. The pressurized fluid is stored in accumulators on the surface and subsea to operate the BOPs. The fluid stored subsea in accumulators may also be used to shear and/or to support acoustic functions when the control of the well is lost. The accumulator 30 may include containers (canisters) that store the hydraulic fluid under pressure and provide the necessary pressure to open and close the BOPs. The pressure from the accumulator 30 is carried by pipe 32 to BOPs 26 and 28 .
[0009] As understood by those of ordinary skill in the art, in deep-sea drilling, in order to overcome the high hydrostatic pressures generated by the seawater at the depth of operation of the BOPs, the accumulator 30 has to be initially charged to a pressure above the ambient subsea pressure. Typical accumulators are charged with nitrogen but as precharge pressures increase, the efficiency of nitrogen decreases which adds additional cost and weight because more accumulators are required subsea to perform the same operation on the surface. For example, a 60-liter (L) accumulator on the surface may have a useable volume of 24 L on the surface but at 3000 m of water depth the usable volume is less than 4 L. To provide that additional pressure deep undersea is expensive, the equipment for providing the high pressure is bulky, as the size of the canisters that are part of the accumulator 30 is large, and the range of operation of the BOPs is limited by the initial pressure difference between the charge pressure and the hydrostatic pressure at the depth of operation.
[0010] In this regard, FIG. 2 shows the accumulator 30 connected via valve 34 to a cylinder 36 . The cylinder 36 may include a piston (not shown) that moves when a first pressure on one side of the piston is higher than a second pressure on the other side of the piston. The first pressure may be the hydrostatic pressure plus the pressure released by the accumulator 30 while the second pressure may be the hydrostatic pressure. Therefore, the use of pressured canisters to store high-pressure fluids to operate a BOP make the operation of the offshore rig expensive and require the manipulation of large parts.
[0011] As discussed above with regard to FIG. 2 , the accumulator 30 is bulky because of the low efficiency of nitrogen at high pressures. As the offshore fields are located deeper and deeper (in the sense that the distance from the sea surface to the seabed is becoming larger and larger), the nitrogen based accumulators become less efficient given the fact that the difference between the initial charge pressure to the local hydrostatic pressure decreases for a given initial charge, thus, requiring the size of the accumulators to increase (it is necessary to use 16 320-L bottles or more depending on the required shear pressure and water depth), and increasing the price to deploy and maintain the accumulators.
[0012] As disclosed in U.S. patent application Ser. No. 12/338,652, attorney docket no. 236466/0340-005, filed on Dec. 18, 2008, entitled “Subsea Force Generating Device and Method” to R. Gustafson, the entire disclosure of which is incorporated herein, a novel arrangement, as shown in FIG. 3 , may be used to generate the force F. FIG. 3 shows an enclosure 36 that includes a piston 38 capable of moving inside the enclosure 36 . The piston 38 divides the enclosure 36 into a chamber 40 , defined by the cylinder 36 and the piston 38 . Chamber 40 is called the closing chamber. Enclosure 36 also includes an opening chamber 42 as shown in FIG. 3 . The enclosure 36 may be formed in a BOP and the opening chamber 42 and the closing chamber 40 actuate the ram block (not shown) connected to rod 44 .
[0013] The pressure in both chambers 40 and 42 may be the same, i.e., the sea pressure (ambient pressure). The ambient pressure in both chambers 40 and 42 may be achieved by allowing the sea water to freely enter these chambers via corresponding valves (not shown). Thus, as there is no pressure difference on either side of the piston 38 , the piston 38 is at rest and no force F is generated.
[0014] When a force is necessary to be supplied for activating a piece of equipment, the rod 44 associated with the piston 38 has to be moved. This may be achieved by generating a pressure imbalance on two sides of the piston 38 .
[0015] Although the arrangement shown in FIG. 3 and described in patent application Ser. No. 12/338,652, attorney docket no. 236466/0340-005, to R. Gustafson discloses how to generate the undersea force without the use of the accumulators, however, as discussed later, the accumulators still may be used to supply a supplemental pressure. FIG. 3 shows that the opening chamber 42 may be connected to a low pressure recipient 60 . A valve 62 may be inserted between the opening chamber 42 and the low pressure recipient 60 to control the pressures between the opening chamber 42 and the low pressure recipient 60 .
[0016] As shown in FIG. 3 , when there is no need to supply the force, the pressure in both the closing and opening chambers is P amb while the pressure inside the recipient 60 is approximately P r =1 atm or lower to improve efficiency. When a force is required for actuation of a piece of equipment of the rig, for example, a ram block of the BOP, the seawater is prevented to enter the opening chamber 42 and valve 62 opens such that the opening chamber 42 may communicate with the low pressure recipient 60 . The following pressure changes take place in the closing chamber 40 , the opening chamber 42 and the low pressure recipient 60 . The closing chamber 40 remains at the ambient pressure as more seawater enters via pipe 64 to the closing chamber 40 as the piston 38 starts moving from left to right in FIG. 4 . The pressure in the opening chamber 42 decreases as the low pressure P r becomes available via the valve 62 , i.e., seawater from the opening chamber 42 moves to the low pressure recipient 60 to equalize the pressures between the opening chamber 42 and the low pressure recipient 60 . Thus, a pressure imbalance occurs between the closing chamber 40 and the opening chamber 42 (which is now sealed from the ambient) and this pressure imbalance triggers the movement of the piston 38 to the right in FIG. 3 , thus generating the force F.
[0017] One feature of the device shown in FIG. 3 is the fact that the low pressure recipient 60 has a limited functionality. More specifically, once the seawater from the opening chamber 42 was released into the low pressure recipient 60 and the opening chamber 42 was sealed from ambient, the low pressure recipient 60 cannot again supply the low pressure unless a mechanism is implemented to empty the low pressure recipient 60 of the received sea water. In other words, the seawater that occupies the low pressure recipient 60 after valve 62 has been opened, has to be removed and the gas at the atmospheric pressure that existed in the low pressure recipient 60 prior to opening the valve 62 has to be reestablished for recharging the low pressure recipient 60 .
[0018] According to an exemplary embodiment and as shown in FIG. 4 , the low pressure recipient 60 may be reused by providing a reset recipient 70 connected to the low pressure recipient 60 , as described in U.S. patent application Ser. No. 12/338,669, attorney docket no. 236956/0340-008, filed on Dec. 18, 2008, entitled “Rechargeable Subsea Force Generating Device and Method” to R. Gustafson, the entire disclosure of which is incorporated herein. The reset recipient 70 and the low pressure recipient 60 may be formed integrally, i.e., in one piece. FIG. 4 shows the low pressure recipient 60 and the reset recipient 70 formed in a single reset module 72 .
[0019] The low pressure recipient 60 may include a movable piston 74 that defines a low pressure gas chamber 76 . This low pressure gas (or vacuum) chamber 76 is the chamber that is filled with gas (air for example) at atmospheric pressure and provides the low pressure to the opening chamber 42 of the BOP. The low pressure recipient 60 may include a port 78 , which may be a hydraulic return port to the BOP.
[0020] A piston assembly 80 penetrates into the low pressure recipient 60 . The piston assembly 80 is provided in the reset recipient 70 . The piston assembly 80 includes a piston 82 and a first extension element 84 . The piston 82 is configured to move inside the reset recipient 70 while the first extension element 84 is configured to enter the low pressure recipient 60 to apply a force to the piston 74 . The piston 82 divides the reset recipient 70 into a reset opening retract chamber 86 and a reset closing extend chamber 88 . The reset opening retract chamber 86 is configured to communicate via a port 90 with a pressure source (not shown). The reset closing extend chamber 88 is configured to communicate via a port 92 to the pressure source or another pressure source. The release of the pressure from the pressure source to the reset recipient 70 may be controlled by valves 94 and 96 . A solid wall 98 may be formed between the low pressure recipient 60 and the reset recipient 70 to separate the two recipients. A second extension element 100 of the piston 82 may be used to lock the piston 82 . The piston 82 may be locked in a desired position by a locking mechanism 102 . Mechanisms for locking a piston are know in the art, for example, Hydril Multiple Position Locking (MPL) clutch, from Hydril Company LP, Houston, Tex. or other locking device such as a collet locking device or a ball grip locking device.
[0021] However, it would be desirable to provide other systems and methods for recharging the low pressure recipient.
SUMMARY
[0022] According to one exemplary embodiment, there is a recharging mechanism for resetting a pressure in a low pressure recipient connected to a subsea pressure control device. The recharging mechanism includes the low pressure recipient configured to have first and second chambers, the first chamber being configured to receive a hydraulic liquid at a high pressure and the second chamber being configured to include a gas at a low pressure; a valve fluidly connected to a first port of the first chamber of the low pressure recipient; a pumping device fluidly connected to a second port of the first chamber of the low pressure recipient; and a blowout preventer (BOP) section fluidly connected to the valve and configured to close or open a ram block. The pumping device is configured to evacuate the hydraulic fluid from the first chamber of the low pressure recipient when the valve closes a fluid communication between the first port of the first chamber and the BOP section.
[0023] According to another exemplary embodiment, there is a pumping device configured to reestablish a low pressure in a low pressure recipient connected to a subsea pressure control device. The pumping device includes first and second enclosures connected to each other by a passage; a piston provided in the first enclosure to split the first enclosure in first and second chambers; a first port connected to the first chamber and configured to fluidly communicate with a source of high pressure; a second port connected to the second chamber and configured to fluidly communicate with the source of high pressure; and a rod connected to the piston and configured to extend through the first enclosure, the passage and the second enclosure in such a way that a fluid from the second enclosure is prevented to enter the first enclosure.
[0024] According to still another exemplary embodiment, there is a method for reestablishing a low pressure in a low pressure recipient with a pumping device. The method includes a step of connecting first and second enclosures of the pumping device to each other by a passage; a step of providing a piston in the first enclosure that splits the first enclosure in first and second chambers; a step of connecting a first port to the first chamber to fluidly communicate with a source of high pressure; a step of connecting a second port to the second chamber to fluidly communicate with the source of high pressure; and a step of connecting a rod to the piston to extend through the first enclosure, the passage and the second enclosure in such a way that a fluid from the second enclosure is prevented to enter the first enclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate one or more embodiments and, together with the description, explain these embodiments. In the drawings:
[0026] FIG. 1 is a schematic diagram of a conventional offshore rig;
[0027] FIG. 2 is a schematic diagram of an accumulator for generating an undersea force;
[0028] FIG. 3 is a schematic diagram of a low pressure recipient connected to a BOP;
[0029] FIG. 4 is a schematic diagram of a device for recharging a low pressure recipient;
[0030] FIG. 5 is a schematic diagram of a pumping system for recharging a low pressure recipient according to an exemplary embodiment;
[0031] FIG. 6 is a more detailed schematic diagram of a pumping system for recharging a low pressure recipient according to an exemplary embodiment;
[0032] FIG. 7 is a schematic diagram of a device used to control an undersea well;
[0033] FIG. 8 is a schematic diagram of a pumping system according to an exemplary embodiment; and
[0034] FIG. 9 is a flow chart of a method for recharging a low pressure recipient according to an exemplary embodiment.
DETAILED DESCRIPTION
[0035] The following description of the exemplary embodiments 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. The following embodiments are discussed, for simplicity, with regard to the terminology and structure of BOP systems. However, the embodiments to be discussed next are not limited to these systems, but may be applied to other systems that require the repeated supply of force when the ambient pressure is high such as in a subsea environment, as for example a subsea pressure control device.
[0036] Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
[0037] According to an exemplary embodiment, a novel way to recharge a low pressure recipient is discussed next. According to this embodiment, a pump may be connected to the low pressure recipient to remove the seawater or other fluid and reestablish a low pressure of a gas inside the low pressure recipient. The pump may be configured to vent into the sea the seawater from the low pressure recipient or to recirculate the seawater. The pump may be configured to handle one or more low pressure recipients. The pump may be placed undersea, next to the low pressure recipient or on a ship above the well.
[0038] According to an exemplary embodiment illustrated in FIG. 5 , a recharging system 110 may include the low pressure recipient 60 , a pumping device 120 , a BOP section 140 , and a valve 140 . The pumping device 120 may have ports 122 and 124 that activate the pumping device for removing the seawater from the low pressure recipient 60 . A fluid connection 160 (e.g., pipe) is provided between the pumping device 120 and the low pressure recipient 60 .
[0039] Valve 150 is configured to place in fluid communication the low pressure recipient 60 with an opening chamber 142 the BOP section 140 and also to allow a pressure source 170 to provide pressure to the BOP section 140 , as will be discussed later. Another pressure source may be connected to a closing chamber 144 of the BOP section 140 and this pressure source may include another low pressure recipient 180 , one or more accumulators 182 , and/or a pipe 184 connected to a ship (not shown) at the sea level. All these power sources are connected to a port 186 of the BOP section 140 . Pipe 184 may be connected to a pump provided on the ship. BOP section 140 is part of a BOP and includes the closing and opening mechanism for a ram block 146 that is connected via a rod 148 to a piston 149 . The pressure differences on the piston 149 , pressures created in the closing chamber 144 and the opening chamber 142 , determine the movement direction of the ram block 146 .
[0040] According to an exemplary embodiment illustrated in FIG. 6 , the low pressure recipient 60 has a piston 74 that separates gas chamber 76 from chamber 77 . However, according to another exemplary embodiment, the piston 74 may be removed as the gas in the gas chamber 76 separates from a fluid in the chamber 77 due, for example, to gravity. Gas chamber 76 is configured to hermetically seal a gas provided in this chamber. The gas is provided at sea level to have a pressure around 1 atm. One possible gas is air. However, it is possible to provide vacuum in gas chamber 76 . Optional piston 74 is provided with seals (not shown) where contacting the inside wall of the low pressure recipient 60 to prevent an escape of the gas from gas chamber 76 or to prevent sea water (or other fluid) from chamber 77 entering the gas chamber 76 . Thus, in one application, gas chamber 76 is completely isolated from ambient or other mediums, i.e., there are no ports or valves connected to the gas chamber 76 . On the contrary, chamber 77 is connected via a first port 79 a to the valve 150 and to the BOP section 140 and via a second port 79 b to pipe 160 and to the pumping device 120 .
[0041] Pumping device 120 may include a pump or a similar device that is capable of moving a fluid. According to an exemplary embodiment, the pumping device 120 includes a first enclosure 126 and a second enclosure 128 connected to each other via a passage 130 . The first enclosure 126 has a larger cross-sectional area A 1 than a cross-sectional area A 2 of the second enclosure 128 . The cross-sectional areas A 1 and A 2 represent the area of each of the enclosures taken substantially perpendicular on axis X along which a piston 132 moves inside the first enclosure 126 . Piston 132 is connected to a rod 134 that extends in the first enclosure 126 , the passage 130 , and the second enclosure 128 . A cross-sectional area A 3 of the rod 134 may be smaller than area A 2 . Optionally, a piston 136 having area A 3 may be connected to the rod 134 . Areas A 1 to A 3 may be chosen to amplify the effect on the pump. By providing an appropriate pressure at ports 122 and/or 124 , the piston 132 is forced to move along axis X. Thus, rod 134 moves inside the second chamber 128 to absorb fluid from chamber 77 and to discharge the absorbed fluid outside the pumping device 120 .
[0042] A movement of the rod 134 along a direction opposite to X absorbs the seawater from chamber 77 of the low pressure recipient 60 . A movement of the rod 134 along X forces the seawater absorbed from chamber 77 along pipe 137 . Valves 190 and 192 (directional valves configured to allow a flow only in one direction) prevent the seawater from entering back into chamber 77 or absorbing the seawater along pipe 137 . Pipe 137 may be configured to release the seawater in the ambient or may send the seawater along pipe 194 and 174 to the pressure source 170 . Piston 132 may have a seal 138 for reducing fluid communication between the chambers 126 a and 126 b of the first enclosure 126 .
[0043] Chamber 77 of the low pressure recipient 60 also communicates with valve 150 . Valve 150 may be a conventional sub plate mounted (SPM) valve or other known valve. An SPM valve is actuated between the various positions by a pilot valve 152 . The pilot valve 152 may be a solenoid valve (electrically activated valve). The pilot valve 152 is connected to the SPM valve 150 as shown in the figure.
[0044] In one application, both the SPM valve 150 and the pilot valve 152 are provided in the MUX POD (not shown) device. The MUX POD may be located on the lower marine riser package (LMRP) while the BOP section 140 is located on the BOP stack. In this regard, FIG. 7 schematically illustrates the possible distribution of the elements discussed above. In this exemplary embodiment, the well head 200 is connected to the sea floor 202 and also to the BOP stack 204 . The BOP stack 204 is connected to the LMRP 206 which in turn is connected via a riser 208 to a ship 210 at sea level 212 . The MUX POD 214 , which hosts the SPM valve 150 and the pilot valve 152 may be located on the LRMP 206 . In other embodiment, the SPM valve 150 and the pilot valve 152 are located in a kicker pod 216 that is located on the BOP stack 204 . The kicker pod 216 may include two connecting parts, one including the SPM valve 150 and one including the pilot valve 152 . The part including the SPM valve 150 may be fixedly connected to the BOP stack 204 while the part including the pilot valve 152 is removably connected to the other part. Thus, the part including the pilot valve 152 may be removed by a remote operated vehicle (ROV) from the BOP stack 204 .
[0045] Returning to FIG. 6 , SPM valve 150 may include various ports 150 a to 150 d, which are configured to block or allow a fluid flow as indicated by the figure. Port 150 b communicates with chamber 77 of the low pressure recipient 60 and blocks a fluid communication between chamber 77 and the BOP section 140 . Port 150 c allow a communication between pressure source 170 and the BOP section 140 . When activated to the other position, port 150 a of the SPM valve 150 blocks the fluid communication with the pressure source 170 and allows fluid communication between chamber 77 and the BOP section 140 . Thus, in the position not shown in FIG. 6 , the fluid in the opening chamber 142 is allowed to enter chamber 77 of the low pressure recipient 60 and to close the ram block 146 (see FIG. 5 ) by moving piston 149 from left to right in the figure.
[0046] After this operation is performed, the SPM valve 150 moves in the position shown in FIG. 6 to block fluid communication to chamber 77 . At this stage, as shown in FIG. 8 , piston 74 (if the low pressure recipient 60 has not piston 74 , the fluid in chamber 77 compresses the gas in chamber 76 ) has compressed the gas in the gas chamber 76 and chamber 77 is full with sea water. This sea water needs now to be removed so that piston 74 may come back to the initial position shown in FIG. 6 . Pumping device 120 is used to achieve this functionality as already discussed.
[0047] Pressure source 170 may be used to provide the necessary high pressure for closing the ram block in the BOP section 140 . The pressure source 170 may include, for example, an enclosure 172 . The enclosure 172 may be configured to hold a fluid under pressure. The enclosure 172 may also be configured to directly communicate via a pipe 174 with the ship 210 for receiving more pressure under given conditions. Alternatively, the enclosure 172 may be connected to the pumping device 120 , via pipe 194 , to boost its pressure.
[0048] According to an exemplary embodiment, at least a pressure sensor may be provided in chamber 76 of the low pressure recipient 60 to monitor the low pressure in this chamber. Further, according to another exemplary embodiment, position detection sensors as described in U.S. Provisional Patent Application Ser. No. 61/138,005, Attorney Docket No. 236460/0340-004, filed on Dec. 16, 2008, to R. Judge, the entire disclosure of which is incorporated herein by reference, may be provided (i) in the pumping device 120 to detect the position of piston 132 , (ii) in the low pressure recipient 60 to detect the position of piston 74 , and/or (iii) in the BOP section 140 to detect the position of piston 149 . Knowing some or all of the positions of the pistons 74 , 132 , and/or 149 , may allow a controller (not shown) to control the release of high pressure from power source 170 to port 152 c and also to control valve 152 and the pumping device 120 .
[0049] According to an exemplary embodiment illustrated in FIG. 9 , there is a method for reestablishing a low pressure in a low pressure recipient with a pumping device. The method includes a step 900 of connecting first and second enclosures of the pumping device to each other by a passage, a step 902 of providing a piston in the first enclosure that splits the first enclosure in first and second chambers, a step 904 of connecting a first port to the first chamber to fluidly communicate with a source of high pressure, a step 906 of connecting a second port to the second chamber to fluidly communicate with the source of high pressure, and a step 908 of connecting a rod to the piston to extend through the first enclosure, the passage and the second enclosure in such a way that a fluid from the second enclosure is prevented to enter the first enclosure.
[0050] The disclosed exemplary embodiments provide a device and a method for repeatedly recharging a low pressure recipient. It should be understood that this description is not intended to limit the invention. On the contrary, the exemplary embodiments are intended to cover alternatives, modifications and equivalents, which are included in the spirit and scope of the invention as defined by the appended claims. Further, in the detailed description of the exemplary embodiments, numerous specific details are set forth in order to provide a comprehensive understanding of the claimed invention. However, one skilled in the art would understand that various embodiments may be practiced without such specific details.
[0051] Although the features and elements of the present exemplary embodiments are described in the embodiments in particular combinations, each feature or element can be used alone without the other features and elements of the embodiments or in various combinations with or without other features and elements disclosed herein.
[0052] This written description uses examples of the subject matter disclosed to enable any person skilled in the art to practice the same, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims. | Method and recharging mechanism for resetting a pressure in a low pressure recipient. The recharging mechanism includes a low pressure recipient configured to have first and second chambers, the first chamber being configured to receive a hydraulic liquid at a high pressure and the second chamber being configured to include a gas at a low pressure. The recharging mechanism further includes a valve fluidly connected to a first port of the first chamber; a pumping device fluidly connected to a second port of the first chamber; and a blowout preventer (BOP) section fluidly connected to the valve and configured to close or open a ram block. The pumping device is configured to evacuate the hydraulic fluid from the first chamber of the low pressure recipient when the valve closes a fluid communication between the first port of the first chamber and the BOP section. | 4 |
This is a division of application Ser. No. 187,170, filed 4/28/88, now U.S. Pat. No. 4,904,67 which is a divisional of application Ser. No. 008,881 filed Jan. 30, 1987, now U.S. Pat. No. 4,767,766 which issued on Aug. 30, 1988.
BACKGROUND OF THE INVENTION
This invention relates to 3-hydroxyazabenzothiophenes having the 2-position substituted with an optionally substituted aryl, aralkyl, alkyl, or alkenyl group, for example, 3-acetyloxy-7-aza-2-phenyl-benzo[b]thiophene.
These novel azabenzothiophenes are found to be either specific 5-lipoxygenase inhibitors or dual 5-lipoxygenase/cyclooxygenase inhibitors and are therefore useful in the treatment of prostaglandin and/or leukotriene mediated diseases.
Among various potent biological mediators derived from the oxygenation of arachidonic acid, prostaglandins and leukotrienes have been linked to various diseases. Notably, the biosynthesis of prostaglandins has been identified as a cause of inflammation, arthritic conditions and pain, and the formation of leukotrienes has been connected to immediate hypersensitivity reactions and pro-inflammatory effects. It has been established that arachidonic acid undergoes oxygenation via two major enzymatic pathways:
(1) The pathway catalyzed by the enzyme cyclooxygenase; and
(2) The pathway catalyzed by the enzyme 5-lipoxygenase.
Interruption of these pathways by enzyme inhibition has been explored for effective therapy. For example, non-steroidal anti-inflammatory drugs (NSAID's) such as aspirin, indomethacin and diflunisal are known cyclooxygenase inhibitors which inhibit the process wherein arachidonic acid is oxygenated via cyclooxygenase to prostaglandins and thromboxanes.
Recently, it has been observed that certain leukotrienes are responsible for diseases related to immediate hypersensitivity reactions such as human asthma, allergic disorders, and skin diseases. In addition, certain leukotrienes and derivatives thereof are believed to play an important role in causing inflammation (B. Samuelsson, Science, 220, 568 (1983); D. Bailey et al, Ann. Rpts. Med. Chem., 17, 203 (1982)).
DETAILED DESCRIPTION OF THE INVENTION
A. SCOPE OF THE INVENTION
The present invention relates to novel compounds of formula (I): ##STR1## or a pharmaceutically acceptable sale thereof wherein N can be at carbon 4, 5, 6 or 7;
X 1 , X 2 and X 3 independently are:
(1) Q, where Q is H; loweralkyl, especially C 1-6 alkyl; haloloweralkyl, especially fluoro or chloro C 1-6 alkyl such as trifluoromethyl; phenyl of formula ##STR2## or naphthyl; or imidazole of formula ##STR3## wherein R 3 is H, C 1-6 alkyl, C 6-14 aryl, C 3-6 cycloalkyl or halo C 1-6 alkyl;
(2) halo, especially chloro, fluoro, or bromo;
(3) loweralkenyl, especially C 2-6 alkenyl, such as ethenyl and allyl;
(4) loweralkynyl, especially C 2-6 alkynyl, for example, ethynyl or n-butynyl;
(5) ##STR4## wherein q is an integer of 0 to 2; (6) --OQ;
(7) --CHQCOQ 1 , where Q 1 is Q and can be the same as or different from Q;
(8) --CHQ(CO)OQ 1 ;
(9) --CH 2 SQ or --CHQSQ 1 ;
(10) --CH 2 OQ or --CHQOQ 1 ;
(11) --COQ;
(12) --(CO)OQ;
(13) --O(CO)Q;
(14) --NQQ 1 ;
(15) --NQ(CO)Q 1 ;
(16) --NQSO 2 Q 1 ;
(17) --SO 2 NQQ 1 ;
(18) --SO 3 Q
(19) --CN;
(20) --NO 2 ;
(21) --CONQQ 1 ;
(22) --NO;
(23) --CSQ 1 ;
(24) --CSNQQ ;
(25) --CF 2 SQ;
(26) --CF 2 O Q;
(27) --NQCONHQ 1 or --NQCONQ 1 Q 2 ; or
(28) -methylenedioxy;
R 1 is
(a) H;
(b) loweralkyl, especially C 1-6 alkyl, such as methyl, ethyl, i-propyl, n-propyl, t-butyl, n-butyl, i-pentyl, n-pentyl, and n-hexyl;
(c) aryl, especially C 6-14 aryl, e.g., naphthyl, anthryl, phenyl or substituted phenyl of formula ##STR5## (d) lowercycloalkyl, especially C 3-6 cycloalkyl, e.g., cyclopropyl, cyclopentyl, and cyclohexyl;
(e) haloloweralkyl, especially halo C 1-6 alkyl, e.g. --CF 3 , --CHF 2 , --CF 2 CF 3 ;
(f) heteroaryl or heteroaryl substituted with X 1 and X 2 especially pyridyl, imidazolyl, pyrryl, furyl or thienyl wherein X 1 and X 2 are as previously defined;
(g) benzyl of formula ##STR6## (h) loweralkynyl, especially C 1-6 alkynyl, such as HC.tbd.C--; CH 3 --C.tbd.C--, or HC.tbd.C--CH 2 --;
(i) loweralkenyl, especially C 1-6 alkenyl, such as CH 2 ═CH--, CH 3 CH═CH--, CH 2 ═CHCH 2 --, CH 3 CH═CH--CH 2 --, (CH 3 ) 2 C═CH-- or --CH═CHCOOR 2 wherein R 2 is loweralkyl, especially C 1-6 alkyl,
(j) aralkenyl of formula ##STR7## wherein Y 1 and Y 2 independently are phenyl and heteroaryl as previously defined;
(k) aralkynyl of formula
--C.tbd.C--Y.sub.1
(1) (CH 2 ) m (CO)R 3 wherein m is an integer of C 1-6 and R 3 is H, C 1-6 alkyl, C 6-14 aryl, C 3-6 cycloalkyl or haloC 1-6 alkyl;
(m) --(CH 2 ) m OR 3 ;
(n) --(CH 2 ) m O(CO)OR 3 ;
(o) --(CH 2 ) m NR 3 R 4 wherein R 4 can be the same or different from R 3 and R 4 is R 3 ;
(p) --(CH 2 ) m --NR 3 (CO)R 4 ;
(q) --(CH 2 ) m (CO)OR 3 ; or ##STR8## R is (a) H;
(b) --(CO)R 3 ;
(c) --(CO)OR 3 ;
(d) --(CO)NR 3 R 4 ;
(e) --(CO)SR 3 ;
(f) --(CH 2 ) m COR 3 ;
(g) --(CH 2 ) m OR 3 ;
(h) --(CH 2 ) m O(CO)OR 3 ;
(i) --(CH 2 ) m NR 3 R 4 ;
(j) --(CH 2 ) m NR 3 (CO)R 4 ;
(k) loweralkyl as previously defined;
(l) lowercycloalkyl as previously defined; or
(m) haloloweralkyl as previously defined; and
p is
0 or 1.
Preferably, an enzyme inhibitor of this invention is of formula: ##STR9## wherein X 1 , X 2 , R and R 1 are as previously defined.
More preferably, an enzyme inhibitor of this invention is of formula: ##STR10## wherein R is H or (CO)CH 3 ;
R 1 is phenyl substituted with X 2 or pyridyl;
X 1 is
(a) H;
(b) C 1-6 alkyl;
(c) halo;
(d) halo-C 1-6 -alkyl, e.g. CF 3 ;
(e) CN;
(f) --(CO)OR 3 ;
(g) --OC 1-6 alkyl;
(h) phenyl--CH(OH)--;
(i) CH 2 S-Aryl; or
(j) --CH 2 S--(CH 2 ) x -aryl; wherein x is 1 to 4;
X 2 is
(a) H;
(b) -methylenedioxy;
(c) halo-C 1-6 alkyl, e.g., CF 3 ;
(d) halo;
(e) CN;
(f) --OC 1-6 alkyl;
(g) --OC 1-6 alkylphenyl;
(h) --(CO)OR 3 ;
(i) C 1-6 alkyl; or
(g) NO 2
B. Preparation of the compounds of the invention
The compounds of the present invention can be divided into four subclasses depending upon the position of the aza substitution in the benzo[b]thiophene ring (position 4, 5, 6, or 7). General procedures, specific examples, and tables of physical data are given below. ##STR11##
Compounds of this subclass are prepared by base-catalyzed (sodium hydride, potassium t-butoxide, lithium diisopropylamide, or thelike) ring closure of an appropriately substituted alkyl or benzyl 2-arylmethylthionicotinate, for example, compound 1 in a solvent, such as dimethylsulfoxide, N,N-dimethylformamide, N-methylpyrrolidinone, tetrahydrofuran, or the like, at a temperature of from ambient to 100° C. for a period of six to twenty-four hours. The required alkyl or benzyl 2-arylmethylthionicotinates (1) are prepared by base-catalyzed (cesium carbonate, diazabicyclo[5,4,0]undec-7-ene(DBU), triethylamine, or the like) esterification of an appropriately substituted 2-arylmethylthionicotinic acid in a solvent such as acetonitrile, tetrahydrofuran, N,N-dimethylformamide, or the like in the presence of a slight excess of alkyl chloride, bromide, or iodide or benzyl chloride or bromide, at a temperature of from ambient to 65° C. for a period of six to twenty-four hours. The methyl nicotinates may also be prepared by treatment with carbonyldiimidazole in a solvent such as N,N-dimethylformamide followed by treatment with sodium methoxide in methanol. The required 2-arylmethylthionicotinic acids (2) are prepared by treatment of the known nicotinic acids (3) with two equivalents of base, such as sodium methoxide in methanol, sodium hydride in N,N-dimethylformamide, or potassium t-butoxide in tetrahydrofuran or the like, at a temperature of from -5° to 25° C. followed by treatment with the appropriately substituted arylmethyl chloride or bromide at ambient temperatures for a period of time from one to 24 hours.
As shown below in scheme (b), selective modification of the 6-position of the pyridine ring, when it is appropriate, can be obtained by treatment of a 2-aryl-3-methoxymethoxy-7-azabenzo[b]thiophene with a nucleophile, such as n-butyllithium or t-butyllithium, in a solvent such as tetrahydrofuran at a temperature from -78° C. to room temperature for 1-24 hours. Alternatively, as shown in scheme (c), modification can be effected by lithiation of the 6-position with a non-nucleophilic base such as trityllithium, followed by treatment with an electrophile, such as benzaldehyde. ##STR12## wherein R 6 is an acid-removable protecting group, e.g. --CH X 2 and Ar are as previously defined. ##STR13##
Substitution in the pyridine ring is also effected via oxidation of the 3-acetyloxy-2-arylbenzo[b]thiophene derivatives (4) to their corresponding N-oxides (5) by treatment with an oxidizing agant, such as m-chloroperbenzoic acid or the like in a solvent such as dichloromethane, tetrahydrofuran, or the like at a temperature of from ambient to 65° C. for a period of time of from one to 24 hours. ##STR14##
Treatment of the pyridine N-oxide derivatives (5) with an acid chloride, such as phosphoryl chloride or the like, affords a mixture of the 4-chloro (6) and 6-chloro (7) derivatives, which function as intermediates to other pyridine ring substituted analogs via nucleophilic displacement reactions and the like. Representative compounds of the 7-aza subclass are listed in Table I.
TABLE I______________________________________2-ARYL-7-AZA-BENZO[b]THIOPHENES______________________________________ ##STR15##X.sub.2 R m.p.______________________________________H H 234-235°3-OCH.sub.3 H 187-189°4-OCH.sub.3 H 209-212°4-OCH.sub.3 COCH.sub.3 140-141°2-OCH.sub.3 H 142-144°H COCH.sub.3 86-87.5°4-CF.sub.3 H 261-264°4-F COCH.sub.3 152-154°4-CF.sub.3 COCH.sub.3 133-134°H COCH.sub.2 OCH.sub.3 88-91°______________________________________ ##STR16##R m.p.______________________________________H 245-248° (d)Ac 115-116°______________________________________ ##STR17## R m.p.______________________________________ CH.sub.2 OMe 54° H 181-183° Ac 128-129°______________________________________
II. 1-Aryl-6-Azabenzo[b]thiophenes
As shown below in scheme (e), compounds of this subclass are prepared by treatment of a 3-halo-4-cyanopyridine (8) with the appropriately substituted arylmethylmercaptide, which was obtained by treatment of the mercapatan with a base, such as soidum methoxide, sodium hydride, triethylamine, lithium diisopropylamide, etc., in a solvent such as acetonitrile, N,N-dimethylformamide, dimethylsulfoxide, tetrahydrofuran at temperatures for -78° C. to 65° C. for 30 minutes to 24 hours. The derived 3-arylmethylthio-4-cyanopyridine are saponified to the corresponding acids with base, such as aqueous soidum hydroxide or potassium hydroxide, followed by acidification. The acids are esterified either by treatment with carbonyldiimidazole in tetrahydrofuran or dimethylformamide for 1-6 hours at 0°-65° C. followed by treatment with methanol for 1-6 hours at room temperatue or by heating with methanol, dimethyoxypropane, and sulfuric acid under reflux for 12-36 hours. The derived methyl-3-arylmethylthiopyridine-4-carboxylates (11) are ring-closed to the 2-aryl-3-hydroxy-6-azabenzo[b]thiophenes (12) and further modified as described for the 7-aza series. ##STR18##
Alternatively, as shown below in scheme (f), the 6-aza series may be derivatized selectively at the 7-position by lithiation with n-butyllithium-TMEDA complex to generate the 7-lithio species, which then can be reacted with an electrophile such as benzaldehyde. ##STR19## III. 2-ARYL-5-AZA-BENZO[b]THIOPHENES
Compounds of this subclass are prepared in an analogous fashion as that described for the 7-aza series, but employing as starting material 4-mercaptonicotinic acid obtained by the process set forth in L. Katz, M. S. Cohen, and W. Schroeder, U.S. Pat. No. 2,824,876 (2-25-58).
Alternatively, the 5-aza-benzol[b]thiophenes can be prepared from 4-chloronicotinic acid by the process set forth in W. C. J. Ross, J. Chem. Soc. (C), 1816 (1966). Displacement of the chloro group by an appropriately substituted arylmethyl mercaptide is carried out in a solvent such as N,N-dimethylformamide, dimethylsulfoxide, tetrahydrofuran, or the like, at a temperature of from 0° to 65° C. for a period of from 30 minutes to 24 hours. The derived 4-aryl-methylthionicotinic acids are than esterified, ring closed and further modified as described for the 7-aza series to the desired 2-aryl-3-hydroxy-5-aza-benzo[b thiophenes (9). ##STR20## IV. 2-Aryl-4-azabenzo[b thiophenes
As illustrated by the following scheme (h), compounds of this subclass are prepared from available methyl 3-hydroxypyridine-2-carboxylates (13). The 3-hydroxy copunds are converted to the 3-mercaptans by treatment of (13) with N,N-dimethyl-aminothiocarbamoyl chloride and a base, such as sodium or potassium hydroxide, in aqueous tetrahydrofuran or dioxane for 1-6 hours at room temperature. The resulting thiocarbamates are isomerized by heating at temperatures between 160°-240° C. in a solvent such as o-dichlorobenzene or m-dimethoxybenzene for 1-8 hours. The N,N-dimethylaminocarbamoyl mercaptans are deblocked by treatment with sodium methoxide-methanol at room temepratue for 10-60 minutes and the resulting mercaptides are alkylated with an arylmethylchloride in a solvent such as tetrahydrofuran, N,N-dimethylformamide, or dioxane at room temperature for 1-24 hours. Ring closure is efected by treatment with base, such as lithium diisopropylamide in tetrahydrofuran at 78° C. or by the methods described for the 7-aza series. ##STR21##
The following examples illustrate but do not limit the present invention.
EXAMPLE 1
Preparation of 7-aza-3-hydroxy-2-(3-methoxyphenyl)benzo[b]thiophene
Step A: Preparation of 2-(3-Methoxybenzylthio)nicotinic acid
A suspension of 4.65 g (0.03 mole) of 2-mercaptonicotinic acid in 100 ml of methanol was cooled in ice as 3.24 g (0.06 mole) of sodium methoxide was added. The resulting solution was left at ice-temperature as 4.68 g (0.03 mole) of 3-methoxybenzyl chloride was added over 5 minutes. The reaction mixture was stirred for 14 hours and the reaction set solid. The addition of 50 ml of water caused solution and an excess of acetic acid precipitated 7.55 g (92% of theory) of 2-(3-methoxybenzylthio)nicotinic acid. Recrystallization was effected from ethyl acetate; m.p. 156°-157° C.
Anal.: Calc'd. for C 14 H 13 NO 3 S. C=61.09; H=4.76, N=5.09. Found: C=61.19, H=4.83, N=5.22.
Step B: Preparation of Methyl 2-(3-methoxybenzylthio)nicotinate
A suspension of 7.15 g (0.026 mole) of 2-(3-methoxybenzylthio)nicotinic acid in 75 ml of dry acetonitrile was treated with 3.95 g (0.026 mole) of 1,8-diazabicyclo[5,4,0]-under-7-ene (DBU). A solution formed and 4.26 g (0.030 mole) of methyl iodide was added over one minute. After keeping the reaction mixture at room temperature for 24 hours, the solution was evaporated in vacuo. The residue was partitioned between 100 ml of ether and 50 ml of water. The ether layer was washed with 50 ml of H 2 O dried, and evaporated to a small volume. The addition of hexane with cooling yielded 6.9 g (92% of theory) of methyl 2-(3-methoxybenzylthio)nicotinate; m.p. 69°-70° C.
Anal.: Calc'd. for C 15 H 15 NO 3 S. C=62.28, H═5.23, N═4.84. Found: C=62.09, H=5.28, N=4.83.
Step C: Preparation of 7-Aza-3-hydroxy-2-(3-methoxyphenyl)-benzo[b]thiophene
To a stirred solution of 5.78 g (0.02 mole) of methyl 2-(3-methoxybenzylthio)nicotinate in 30 ml of dry N-methylpyrrolidinone was added 800 mg (0.02 mole) of 60% sodium hydride dispersion. The reaction was stirred at room temperature for 14 hours then poured into ice water. The solution was extracted with 50 ml of hexane, and the aqueous layer was treated with an excess of acetic acid to precipitate 7-aza-3-hydroxy-2-(3-methoxyphenyl)benzo[b]thiophene; yield 4.4 g (86% of theory). The crude product was recrystallized from ethyl acetate; m.p. 187°-189° C.
Anal.: Calc'd. for C 14 H 11 NO 2 S. C=65.37, H=4.31, N=5.44. Found: C=65.31, H=4.35, N=5.40.
EXAMPLE 2
3-Acetoxy-6-(1,1-dimethylethyl)-2-phenyl-7-azabenzo[b]thiophene
Step A: Preparation of 2-Phenylmethylthionicotinic acid
A sample of 15.5 g (100 mmol) of 2-mercaptonicotinic acid was dissolved in 50 mL of 4.1M sodium methoxide in methanol and 100 mL of methanol. To this was added 18.8 g (110 mmol) of benzyl bromide and the solution was stirred at room temperature for 3 hours. Then 250 mL of water was added and the solution was acidified to pH 7 with glacial acetic acid. The precipitate was collected, washed with water, and dried to afford 22.3 g (91%) of white solid.
Step B: Preparation of Methyl 2-phenylmethylthio
nicotinate
A solution of 18.3 g (75 mmol) of 2-phenylmethylthionicotinic acid and 16.2 g (100 mmol) of carbonyldiimidazole in 250 mL of dry dimethylformamide was stirred at room temperature for 2 hours. The solution was cooled to 0° and 25 mL of 4M sodium methoxide in methanol was added. After warming to room temperature the solution was partitioned between ether and water and the aqueous layer was washed with two portions of ether. The ether extracts were washed with brine, dried over MgSO 4 , and concentrated. The residue was crystallized from ether-hexane to afford 17.4 g (89%) of fine white needles, which was used in the next step without further purification.
Step C: Preparation of 3-Hydroxy-2-phenyl-7-azabenzo[b]thiophene
A suspension of 12.9 g (50 mmol) of methyl 2-phenylmethylthionicotinate and 2.6 g (110 mmol) of sodium hydride in 100 mL of dry N,N-dimethylformamide was stirred for 4 hours at room temperature. The solution was diluted with 200 mL water and acidified with glacial acetic acid. The precipitate was collected, washed with water, and dried to afford 10.6 g (93%) of a white crystalline solid to be used in the next step.
Step D: Preparation of 3-Methoxymethoxy-2-phenyl-7-azabenzothiophene
A suspension of 4.54 g (20 mmol) of 3-hydroxy-2-phenyl-7-azabenzo[b]thiophene and 2.75 g (22 mmol) of potassium t-butoxide in 50 mL of tetrahydrofuran was stirred until the solid dissolved. Then 2.0 g (25 mmol) of chloromethyl methyl ether was added and the solution was stirred at room temperature for 2 hours. The solution was partitioned between ether and water and the aqueous layer was washed with two portions of ether. The ether extracts were washed with brine, dried over MgSO 4 , and concentrated to 4.33 g (80%) of an oil that crystallized upon standing, m.p. 54° C.
Step E: Preparation of 6-(1,1-dimethylethyl)-3-hydroxy-2-phenyl-7-azabenzo[b]thiophene
A solution of 2.72 g (10.0 mmol) of 3-methoxymethoxy-2-phenyl-7-azabenzothiophene in 20 mL of dry tetrahydrofuran was cooled to -78° C. To this was added 11 mL of a 1.0M solution of t-butyllithium in hexane and the solution was allowed to warm to room temperature. The solution was quenched with methanol and stirred in air for 60 minutes, then partitioned between ether and water. The aqueous layer was washed with two portions of ether and the combined extracts were washed with brine, dried, and concentrated to an oil. The oil was dissolved in 10 mL methanol and 10 mL of 2M HCl and stirred at room temperature for 24 hours. The solution was partitioned between ether and water and the ether layer dried and concentrated. Recrystallization from ether-hexane afforded 2.43 g (84%) of pale yellow needles, m.p. 181°-183° C.
Step F: Preparation of 3-Acetoxy-6-(1,1-dimethylethyl)-2-phenyl-7-azabenzo[b]-thiophene
A solution of 1.42 g (5 mmol) of 6-(1,1-dimethylethyl)-3-hydroxy-2-phenyl-7-azabenzo[b]-thiophene and 1.42 g sodium acetate in 20 mL of acetic anhydride was heated at reflux for 1 hour. The solution was concentrated and the residue was partitioned between ether and water. The ether layer was washed with sodium bicarbonate solution and brine, dried and concentrated. The residue was crystallized from ether-hexane to afford 1.49 g (91%) of fine white needles, m.p. 128°-9° C.
EXAMPLE 3
3-Hydroxy-2-(4-methoxyphenyl)-6-azabenzo[b]thiophene
Step A: Preparation of 4-Cyano-3-(4-methoxyphenyl)-methylmercaptopyridine
A solution of 6.2 g (40 mmol) of p-methoxybenzylmercaptan in 9.8 mL of 4.4M sodium methoxide in methanol was added dropwise to a solution of 5.52 g (40 mmol) of 3-chloro-4-cyanopyridine in dry acetonitrile that has been cooled in an ice bath. After addition was complete the solution was allowed to warm to room temperature over 2 hours. The solvent was concentrated and the residue was partitioned between dichloromethane and water. The aqueous layer was extracted with two portions of dichloromethane and the combined extracts were washed with brine, dried (MgSO 4 ) and concentrated to afford 6.1 g (60%) of a pale yellow crystalline solid, m.p. 80°-81° C.
Step B: Preparation of 3-(4-methoxyphenyl)methylthiopyridine-4-carboxylic acid
A solution of 6.0 g (23.4 mmol) of 4-cyano-3-(methoxyphenyl)methylthiopyridine in 15 mL of 6M NaOH was heated under reflux for 6 hours. The solution was cooled, and acidified with glacial acetic acid. The precipitate was collected by filtration and triturated with two portions of cold ether to afford 6.0 g (94%) of white crystals, m.p. 250° C. (decomp.).
Step C: Preparation of Methyl 3-(4-methoxyphenyl) methylthiopyridine-4-carboxylate
A solution of 4.9 g (17.8 mmol) of 3-(4-methoxyphenyl)methylthiopyridine-4-carboxylic acid and 4.9 g (30 mmol) of carbonyldiimidazole in 50 mL of dry N,N-dimethylformamide was stirred at 0° C. for 10 minutes and then allowed to warm to room temperature. After 2 hours the solution was cooled to 10° C. and quenched with 20 mL of methanol. The mixture was stirred for 2 hours and then the solvent was concentrated. The residue was partitioned between ether and water and the aqueous layer was extracted with three portions of ether. The ether extracts were dried (MgSO 4 ) and concentrated to afford 5.1 g (93%) of a crystalline solid, m.p. 99°-100° C.
Step D: Preparation of 3-Acetoxy-2-(4-methoxyphenyl)-6-azabenzo[b]thiophene
A solution of 0.200 g (.69 mmol) of methyl 3-(4-methoxyphenyl)methylthiopyridine-4-carboxylate in 2 mL of dry tetrahydrofuran was added to a suspension of 83 mg (2.1 mmol) of 60% dispersion of sodium hydride in 2 mL of dry N,N-dimethylformamide. The mixture was stirred at room temperature for 3 hours, then poured onto ice water and acidified with glacial acetic acid. The solid material (product) was collected by filtration and the filtrate was extracted with ethyl acetate. The ethyl acetate extract was dried, concentrated and combined with the solid precipitate that had been collected. This material was heated at reflux with 100 mg sodium acetate in 2 mL of acetic anhydride for 2 hours, then was partitioned between ethyl acetate and water. The aqueous layer was washed with two portions of ethyl acetate and the combined extracts were dried and concentrated. The residue was crystallized from methanol to afford 100 mg (48%) of white crystalline material, m.p. 141°-142° C.
EXAMPLE 4
3-Acetoxy-2-phenyl-6-azabenzo[b]thiophene
Step A: Preparation of 4-Cyano-3-phenyl-methyl
thiopyridine
Prepared from 4.3 g (31.1 mmol) of 3-chloro-4-cyanopyridine as in example , Step A., except that benzylmercaptan was used instead of p-methoxybenzylmercaptan to afford 6.1 g (87%) of a pale unstable oil that was used directly in step B.
Step B: Preparation of 3-Phenylmethylthiopyridine-4
carboxylic acid
Prepared from 6.1 g of material from Step A by the procedure described in example, Step B to afford 5.7 g (86%) of white crystalline material, m.p. 240°-5° C, (decomp.).
Step C: Preparation of Methyl 3-phenylmethylthiopyridine-4-carboxylate
A solution of 5.1 g (20 mmol) of 3-phenylmethylthiopyridine-4-carboxylic acid in 150 mL of methanol, 1.6 mL of 2,2-dimethoxypropane, and 5 mL of sulfuric acid was heated at reflux for 18 hours. The solution was cooled, concentrated to 25 mL, then partitioned between ether and sodium bicarbonate solution. The ether layer was washed with sodium bicarbonate solution, then brine, then dried and concentrated to afford 5.0 g (96%) of white crystals, m.p. 79°-80° C.
Step D: Preparation of 3-Hydroxy-2-phenyl-6-azabenzo[b]thiophene
A solution of 4.8 g (19 mmol) of methyl 3-phenylmethylthiopyridine-4-carboxylate in 10 mL of tetrahydrofuran was added to a slurry of 2.40 g (60 mmol) of 60% sodium hydride in 10 mL of N,N-dimethylformamide and the resulting mixture was stirred at 60° C. for 3 hours. The solution was poured onto ice water and acidified with glacial acetic acid. The filtrate was collected to afford 1.6 g (38%) of white solid.
Step E: Preparation of 3-Methoxymethoxy-2-phenyl-6-azabenzo[b]thiophene
A solution of 1.1 g (4.8 mmol) 3-hydroxy-2-phenyl-6-azabenzo[b]thiophene and 0.116 g (4.8 mmol) of sodium hydride in 15 mL of tetrahydrofuran was stirred at room temperature for 15 minutes. Then 0.37 mL (5.0 mmol) of chloromethyl methyl ether was added and the solution was stirred at room temperature for 2 hours. The solution was partitioned between ether and water and the ether extract was concentrated to afford 1.2 g (92%) of white crystalline material, m.p. 55°-56° C.
Step F: Preparation of 7-(Hydroxyphenylmethyl)-3-methoxymethoxy-2-phenyl-6-azabenzo[b]thiophene
A solution of 0.43 g (3.7 mmol) of N,N,N',N'-tetramethylethylenediamine and 1.8 mL of 2.6M n-butyllithium was stirred at -20° for 1 hour, then cooled to -60° .
A solution of 1.0 g (3.7 mmol) of 3-methoxymethoxy-2-phenyl-6-azabenzo[b]thiophene in 5 mL of dry ether was added and the solution was kept at -60° for 3 hours. The reaction was quenched with 0.5 mL of benzaldehyde and allowed to warm to room temperature. The mixture was partitioned between ether and water and the aqueous layer was washed with ether. The combined extracts were dried and concentrated to an oil. Chromatography on silica gel (30% ethyl acetate-hexane) afforded 0.62 g (44%) of a colorless oil, NMR (200 MHz, CDCl 3 ) δ3.4 (s, 3H), 5.0 (s, 2H), 5.95 (s, 1H, --OH), 7.2-7.8-(m, 12H), 8.52 (d, J=6Hz, IH), Mass Spec m/e 377 (M+).
Step G: Preparation of 7-(Hydroxyphenylmethyl)-3-hydroxy-2-phenyl-6-azabenzo[b]thiophene
A solution of 0.61 g (1.8 mmol) of 7-(hydroxyphenylmethyl)-3-methoxymethyl-2-phenyl-6-azabenzo[b]thiophene in 2.7 mL of 2M HCl and 2.7 mL of methanol was heated at reflux for 30 minutes. The solution was cooled and partitioned between ethyl aoetate and water. The ethyl acetate layer was dried and concentrated to afford 0.50 g (93%) of white solid, m.p. 214-215° C.
EXAMPLE 5
5-Aza-3-hydroxy-2-phenylbenzo[b]thiophene
Step A: Preparation of 4-Benzylthionicotinic acid mole)
To a stirred suspension of 1.55 g (0.01 mole) of 4-mercaptonicotinic acid (prepared by the process set forth in L. Katz, M. S. Cohen, and W. Schroeder, U.S. Pat. No. 2,824,876) in 20 mL of dry methanol cooled in ice and stirred, was added 1.08 g (0.02 mole) of sodium methoxide. The yellow solution was cooled in ice and 1.71 g (0.01 mole) of benzyl bromide was added. Within one hour there was a new solid formation with loss of the yellow color. The reaction was kept for 2 more hours at room temperature, then most of the solvent was removed in vacuo. The solid residue was taken up in 50 mL of water and acidified with an excess of acetic acid to precipitate 2.45 g (100% of theory) of 4-(benzylthio) nicotinic acid which melted at 232-234° C.
Step B: Preparation of Methyl 4-benzylthionicotinate
A suspension of 2.45 g (0.01 mole) of 4-benzylthionicotinic acid in 35 mL of dry acetonitrile was treated with 1.52 g (0.01 mole) of 1,8-diazabicyclo[5,4,0]under-7-ene (DBU). 1.7 g (0.01 mole) of methyl iodide was added and stirring was continued for 7 hours. The reaction was carefully diluted with water to crystallize 430 mg of methyl 4-benzylthionicotinate which melted at 98°-99° C.
Anal.: Calc'd. C 14 H 13 NO 2 S. C=64.86, H=5.05, N=5.40. Found: C=65.11, H=5.28, N=5.65.
Step C: Preparation of 5-Aza-3-hydroxy-2-phenylbenzo[b]thiophene
A solution of 3.36 g (0.03 mole) of potassium tert-butoxide in 90 mL of dry tetrahydrofuran was cooled to ice-temperature and stirred as 2.59 g (0.01 mole) of methyl 4-benzylthionicotinate was added. The yellow-orange solution was stirred at ice-temperature for 15 minutes, then at room temperature overnight. Most of the tetrahydrofuran was evaporated in vacuo. The residue was taken up in 100 mL of ice water and heated with an excess of acetic acid to obtain 1.91 g (84% of theory) of 5-aza-3-hydroxy-2-phenylbenzo[b]thiophene, which was) recrystallized from N,N-dimethylformamide-ether giving a melting point of 260° C.
Anal.: Calc'd. for C 13 H 9 NOS. C=68.72, H=3.99, N=6.16. Found: C=68.34, H=4.09, N=6.18.
EXAMPLE 6
(3-Acetyloxy-5-aza-2-phenylbenzo[b]thiophene
A mixture of 200 mg of 5-aza-3-hydroxy-2-phenylbenzo[b]thiophene, 10 mg of p-toluenesulfonic acid, and 2 mL of acetic anhydride was heated on a steam bath for three hours, then evaporated in vacuo. The residue was taken up in 15 mL of ethyl acetate and 15 mL of ether, washed with 10 mL of 1% sodium bicarbonate solution, dried, concentrated to a small volume, and finally diluted with hexane to crystallize 155 mg (65% of theory) of 3-acetyloxy-5-aza-2-phenylbenzo[b]thiophene; m.p. 101°-103° C.
Anal.: Calc'd. for C 15 H 11 NO 2 S. C=66.91, H=4.12, N=5.20. Found: C=66.96, H=4.19, N=5.53.
EXAMPLE 7
5-Aza-3-hydroxy-2-(4-methoxyphenyl)--benzo[b]thiophene
Step A: Preparation of 4-(4-methoxybenzylthio)nicotinic acid
A stirred and ice-cooled mixture of 788 mg (0.005 mole) 4-chloronicotinic acid [prepared by the process set forth in W. C. J. Ross, J. Chem. Soc. (C), 1816 (1966)]and 771 mg (0.005 mole) of 4-methoxybenzylmercaptan in 6 mL of dry N,N-dimethylformamide was treated with 480 mg (0.012 mole) of 60% sodium hydride dispersion. The reaction was stirred at room temperature for 4 hours during which a thick solid formed, which was taken up in 75 mL of ice water. After extraction with 25 mL of hexane, the aqueous layer was acidified with 2.5N hydrochloric acid to precipitate 4-(4-methoxybenzylthio)--nicotinic acid; yield 1.2 g (89% of theory), m.p. 230° C.
Step B: Preparation of Methyl 4-(4-methoxybenzylthio)nicotinate
A suspension of 2.2 g (0.008 mole) of 4-(4-methoxybenzylthio)--nicotinic acid in 30 mL of dry N,N-dimethylformamide was reacted with 1.78 g (0.011 mole) of 1,1'-carbonyldiimidazole. This was stirred at room temperature for 2 hours, then 0.5 mL of 4.3M sodium methoxide in methanol and 5 mL of methanol. The reaction was stirred for 1 hour at room temperature, then partitioned between 75 mL of ether and 30 mL of water. The ether layer was extracted with 2×30 mL of water, dried, concentrated to a small volume, and hexane added to crystallize methyl 4-(4-methoxybenzylthio) nicotinate; yield 1.66 g (72% of theory), m.p. 108°-110° C.
Anal.: Calc'd. for C 15 H 15 NO 3 S. C=62.28, H=5.23, N=4.84. Found: C=62.41, H=5.41, N=4.69.
Step C: Preparation of 5-Aza-3-hydroxy-2-(4-methoxy
phenyl)benzo[b]thiophene
A solution of 672 mg (0.006 mole) of potassium tert-butoxide in 10 mL of dry tetrahydrofuran was stirred at ice-temperature while 579 mg (0.002 mole) of methyl 4-(4-methoxybenzylthio) nicotinate was added over 3 minutes. The yellow solution was stirred for 10 more minutes at ice-temperature, then at room temperature for 21/2 hours. The reaction was diluted with 50 mL of ethyl acetate, and 0.5 mL of acetic acid was added. This was extracted with 3×30 mL of H 2 O. The organic layer was dried and evaporated leaving 230 mg (45% of theory) of 5-aza-3-hydroxy-2-(4-methoxyphenyl)-benzo[b]thiophene. Recrystallization was effected
(25 from tetrahydrofuran, m.p. 222-225° C.
Anal.: Calc'd. for C 14 Hhd 11NO 2 S. C=65.37, H=4.31, N=5.44. Found: C=65.09, H=4.50, N=5.29.
(5-Aza-3-hydroxy-2-(4-methoxyphenyl)benzo[b]thiophene can also be prepared by dissolving methyl 4-(4-methoxybenzylthio)nicotinate in 8 mL of dry N,N-dimethylformamide. This was stirred and cooled in ice as 120 mg (0.005 mole) of NaH was added. After reaction was stirred at room temperature overnight, it was diluted with 100 mL of ice water and decolorized with charcoal. An excess of acetic acid precipitated 5-aza-3-hydroxy-2-(4-methoxyphenyl)benzo[b]thiophene; yield 575 mg (75% of theory), m.p. 223°-225° C.
EXAMPLE 8
3-Acetyloxy-5-aza-2-(4-methoxyphenyl)benzo[b]thiophene
A mixture of 500 mg of 5-aza-3-hydroxy-2-(4-methoxyphenyl)benzo[b]thiophene, 20 mg of p-toluenesulforic acid, and 8 mL of acetic anhydride was heated on a steam bath for 3 hours, then evaporated. The crystalline residue was triturated with water, then recrystallized from methylene chloride-hexane to give 360 mg (62% of theory) of 3-acetyloxy-5-aza-2-(4-methoxyphenyl)benzo[b]thiophene, m.p. 125°-127° C.
Anal.: Calc'd. for C 16 H 13 NO 3 S. C=64.21, H=4.38, N=4.68. Found: C=64.56, H=4.19, N=4.43.
EXAMPLE 9
3-Acetyloxy-2-(4-methoxyphenyl)-4-azabenzo[b]thiophene
Step A: Preparation of Methyl 3-(N,N-dimethyl-aminothiocarbamoyloxy)pyridine-2-carboxylate
A solution of 3.06 g (20 mmol) of methyl 3-hydroxypyridine-2-carboxylate in 15 mL of water was made basic with 1.12 g KOH. To this solution was added 3.2 g (26 mmol) of N,N-dimethylaminothiocarbamoyl chloride and the solution was stirred at room temperature for 2 hours. The solution was partitioned between benzene and water and the aqueous layer was washed with two portions of water. The combined extracts were dried and concentrated to afford 4.1 g of a white solid, m.p. 74°-75° C.
Step B: Preparation of Methyl 3-(N,N-dimethylaminocarbamoylthio)pyridine-2-carboxylate
A solution of 2.9 g (12.1 mmol) of methyl 3-(N,N-dimethylaminothiocarbamoyloxy)pyridine-2-carboxylate in 10 mL of m-dimethoxybenzene was heated to 230° for 2 hours. The solution was cooled and filtered through silica with hexane to remove the m-dimethoxybenzene. Then the silica was washed with acetone to afford 2.4 g (83%) of a pale tan solid, m.p. 56°-58° C.
Step C: Preparation of Methyl 3-(4-methoxyphenylmethylthio)pyridine-2-carboxylate
A solution of 1.20 g (5 mmol) of methyl 3-(N,N-dimethylaminocarbamoylthio)pyridine-2-carboxylate in 5 mL of methanol and 1.5 mL (6 mmol) of 4.lM sodium methoxide methanol was stirred at room temperature for 10 minutes. Then the solvent was concentrated and the residue was dissolved in 5 mL of N,N-dimethylformamide and 5 mL of tetrahydrofuran. 0.936 g (6 mmol) of p-methoxybenzylmercaptan was added and the solution was stirred at room temperature for 18 hours. The solution was partitioned between ether and water and the aqueous layer was extracted with two portions of ether. The combined extracts were washed with brine, dried and concentrated. Recrystallization from methanol afforded 0.90 g (62%) of pale tan needles, m.p. 99°-100° C.
Step D: Preparation of 3-Acetyloxy-2-(4-methoxyphenyl)-4-azabenzo[b]thiophene
A solution of 0.65 g (2.24 mmol) of methyl 3-(4-methoxyphenylmethylthio)pyridine-2-carboxylate in 5 mL of dry tetrahydrofuran was added to a solution of 2.6 mmol of lithium diisopropylamide in dry tetrahydrofuran at -78° C. After 30 minutes the solution was partitioned between ether and water and the aqueous layer was saturated with NaCl and washed with two portions of dichloromethane. The combined extracts were dried and concentrated to an oil that was dissolved in 2 mL of acetic anhydride and 200 mg of sodium acetate. This solution was heated at reflux for 1 hour, then partitioned between ether and water. The aqueous layer was washed with two portions of ether and the combined extracts concentrated. The residue was chromatographed on HPLC (silica, 30% ethyl acetate-hexane) to afford 101 mg (15%) of white crystals, m.p. 146°-148° C.
C. Utility of the compounds within the scope of the invention
This invention also relates to a method of treatment for patients (or mammalian animals raised in the dairy, meat, or fur industries or as pets) suffering from disorders or diseases mediated by the inhibition of the oxidation of arachiodonic acid and/or leukotrienes, and gastric irritation or lesion. More specifically, this invention is directed to a method of treatment involving the administration of one or more of the enzyme inhibitors of formula (I) as the active constituent.
Accordingly, a compound of Formula (I) can be used among other things to reduce pain and inflammatory conditions, including rheumatoid arthritis, osterarthritis, gout, psoriasis, inflammatory bowel disease and inflammation in the eye that may be caused by ocular hypertension and may eventually lead to glaucoma. It can also be used to correct respiratory, cardiovascular, and intravascular alterations or disorders, and to regulate immediate hypersensitivity reactions that cause human asthma and allergic conditions.
For the treatment of inflammation, arthritis conditions, cardiovascular disorder, allergy, psoriasis, asthma, or other diseases mediated by prostaglandins and/or leukotrienes, a compound of Formula (I) may be administered orally, topically, parenterally, by inhalation spray or rectally in dosage unit formulations containing conventional non-toxic pharmaceutically acceptable carriers, adjuvants and vehicles. The term parenteral as used herein includes subcutaneous injections, intravenous, intramuscular, intravascular injection or infusion techniques. In addition to the treatment of warm-blooded animals such as mice, rats, horses, cattle, sheep, dogs, cats, etc., the compounds of the invention are effective in the treatment of humans.
The pharmaceutical compositions containing the active ingredient may be in a form suitable for oral use, for example, as tablets, troches, lozenges, aqueous or oily suspensions, dispersible powders or granules, emulsions, hard or soft capsules, or syrups or elixirs. Compositions intended for oral use may be prepared according to any method known to the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents selected from the group consisting of sweetening agents, flavoring agents, coloring agents and preserving agents in order to provide pharmaceutically elegant and palatable preparation. Tablets containing the active ingredient in admixture with non-toxic pharmaceutically acceptable excipients may also be manufactured by known methods. The excipients used may be for example, (1) inert diluents such as calcium carbonate, sodium carbonate, lactose, calcium phosphate or sodium phosphate; (2) granulating and disintegrating agents such as corn starch, or alginic acid; (3) binding agents such as starch, gelatin or acacia, and (4) lubricating agents such as magnesium stearate, stearic acid or talc. The tablets may be uncoated or they may be coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period. For example, a time delay material such as glyceryl monostearate or glyceryl distearate may be employed. They may also be coated by the techniques described in the U.S. Pat. Nos. 4,256,108; 4,160,452; and 4,265,874 to form osmotic therapeutic tablets for controlled release.
In some cases, formulations for oral use may be in the form of hard gelatin capsules wherein the active ingredient is mixed with an inert solid diluent, for example, calcium carbonate, calcium phosphate or kaolin. They may also be in the form of soft gelatin capsules wherein the active ingredient is mixed with water or an oil medium, for example peanut oil, liquid paraffin, or olive oil.
Aqueous suspensions normally contain the active materials in admixture with excipients suitable for the manufacture of aqueous suspensions. Such excipients may be
(1) suspending agents such as sodium carboxymethylcellulose, methylcellulose, hydroxypropylmethylcellulose, sodium alginate, polyvinylpyrrolidone, gum tragacanth and gum acacia;
(2) dispersing or wetting agents which may be
(a) a naturally-occurring phosphatide such as lecithin,
(b) a condensation product of an alkylene oxide with a fatty acid, for example, polyoxyethylene stearate,
(c) a condensation product of ethylene oxide with a long chain aliphatic alcohol, for example, heptadecaethyleneoxycetanol,
(d) a condensation product of ethylene oxide with a partial ester derived from a fatty acid and a hexitol such as polyoxyethylene sorbitol monooleate, or
(e) a condensation product of ethylene oxide with a partial ester derived from a fatty acid and a hexitol anhydride, for example polyoxyethylene sorbitan monooleate.
The aqueous suspensions may also contain one or more preservatives, for example, ethyl or n-propyl p-hydroxybenzoate; one or more coloring agents; one or more flavoring agents; and one or more sweetening agents such as sucrose or saccharin.
Oily suspension may be formulated by suspending the active ingredient in a vegetable oil, for example arachis oil, olive oil, sesame oil or coconut oil, or in a mineral oil such as liquid paraffin. The oily suspensions may contain a thickening agent, for example beeswax, hard paraffin or cetyl alcohol. Sweetening agents and flavoring agents may be added to provide a palatable oral preparation. These compositions may be preserved by the addition of an antioxidant such as ascorbic acid.
Dispersible powders and granules are suitable for the preparation of an aqueous suspension. They provide the active ingredient in admixture with a dispersing or wetting agent, a suspending agent and one or more preservatives. Suitable dispersing or wetting agents and suspending agents are exemplified by those already mentioned above. Additional excipients, for example, th,ose sweetening, flavoring and coloring agents described above may also be present.
The pharmaceutical compositions of the invention may also be in the form of oil-in-water emulsions. The oily phase may be a vegetable oil such as olive oil or arachis oils, or a mineral oil such as liquid paraffin or a mixture thereof. Suitable emulsifying agents may be (1) naturally-occurring gums such as gum acacia and gum tragacanth, (2) naturally-occurring phosphatides such as soy bean and lecithin, (3)esters or partial esters derived from fatty acids and hexitol anhydrides, for example, sorbitan monooleate, (4) condensation products of said partial esters with ethylene oxide, for example, polyoxyethylene sorbitan monooleate. The emulsions may also contain sweetening and flavoring agents.
Syrups and elixirs may be formulated with sweetening agents, for example, glycerol, propylene glycol, sorbitol or sucrose. Such formulations may also contain a demulcent, a preservative and flavoring and coloring agents.
The pharmaceutical compositions may be in the form of a sterile injectable aqueous or oleagenous suspension. This suspension may be formulated according to known methods usinq those suitable dispersing or wetting agents and suspending agents which have been mentioned above. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example as a solution in 1,3-butane diol. Among the acceptable vehicles and solvents that may be employed are water, Ringer's solution and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides. In addition, fatty acids such as oleic acid find use in the preparation of injectables.
A compound of formula (I) may also be administered in the form of suppositories for rectal administration of the drug. These compositions can be prepared by mixing the drug which a suitabIe nonirritating excipient which is solid at ordinary temperatures but liquid at the rectal temperature and will therefore melt in the rectum to release the drug. Such materials are cocoa butter and polyethylene glycols.
For topical use, creams, ointments, jellies, solutions or suspensions, etc., containing the anti-inflammatory agents are employed.
Dosage levels of the order from about 1 mg to about 100 mg per kilogram of body weight per day are useful in the treatment of the above-indicated conditions (from about 50 mg to about 5 gms. per patient per day). For example, inflammation is effectively treated and anti-pyretic and analgesic activity manifested by the administration from about 2.5 to about 75 mg of the compound per kilogram of body weight per day (about 75 mg to about 3.75 gms per patient per day).
D. Biological Data Supporting the Utility of the Compounds Within the Scooe of the Invention.
The following is a summary of biological data from two bioassays. These data serve to illustrate that the compound of formula (I), for example, 7-aza-3-acetyloxy-2-phenyl-benzo[b]-thiophene (compound A) and 7-aza-3-acetyloxy-2-(4-fluorophenyl)--benzo[b]thiophene, (compound B) are useful in the treatment of leukotriene mediated diseases.
1. Brewer's Yeast Hyperalgesia Assay*
In this assay, which is sensitive to inhibition by lipoxygenase and cyclooxygenase inhibitors, compounds of formula I reduced the pain response induced by Brewer's yeast (Table 1a).
Groups of 10 female Sprague-Dawley rats, weighing 35-50 grams (Charles River Breeding Laboratories), were fasted overnight prior to testing. For each animal, 0.1 ml of the edemainducing Brewer's yeast suspension (5% homogenate in physiological saline) was injected into the right hindpaw. Pain threshold was measured by applying pressure to the plantar surface of the hindpaw by means of a compressed air driven piston with a 2 mm. tip. Testing was carried out 3, 4, and 5 hours after the yeast injection. Compounds, prepared as homogenates in either 1% methylcellulose or aqueous vehicle, were administered orally 60 minutes before testing. A group of vehicle treated control animals was included in each experiment. Squeak pressure thresholds were measured and recorded for the compound and vehicle-treated groups of rats 3, 4, and 5 hours after administration of the Brewer's yeast (60 minutes after compound treatment). The estimation of analgesia was as follows: 1. the mean response pressure for the daily vehicle control group in the normal and inflammed foot was calculated; 2. for each compound treatment group, the number of animals with response pressures equal to or greater than 25 mm Hg was noted. These animals were considered to be analgesic.
Following is data obtained using these various assays with representative compounds of Formula I.
TABLE 1a______________________________________Effect of Compounds of Formula (I) on YeastHyperalgesia in the Rat ##STR22## Dose %R X.sup.1 X.sup.2 (mg/kg p.o.) Inhibition______________________________________(CO)CH.sub.3 H H 3 60(CO)CH.sub.3 H p-OCH.sub.3 3 10H H p-OCH.sub.3 3 60(CO)CH.sub.3 H p-F 3 70(CO)CH.sub.2 OCH.sub.3 H H 3 50(CO)CH.sub.3 6-Cl H 3 40(CO)CH.sub.3 6-OCH.sub.3 H 3 60(CO)CH.sub.3 7-OCH.sub.3 H 3 50(CO)CH.sub.3 7-CN H 3 60H 7-CN H 3 50______________________________________
2. Inhibition of PMN 5-lipoxygenase in the rat Methods:
PMN Isolation:
Male Sprague-Dawley rates under ether anesthesia were injected i.p. with 8 mls of 12% aqueous sodium caseinate. After 15°-24 hours the animals were sacrificed with C 02 and the peritoneal cavities were lavaged with Eagles MEM with Earles salts and containing L-glutamine and 30 mM HEPES. The pH was adjusted to 7.4. The lavage fluid was centrifuged for 5 minutes at 350×g at room temperature. The cells were resuspended in fresh medium and filtered through lens paper. The cells were pelleted again and reconstituted to a concentration of 1×10hu 7 cells/ml with fresh medium.
Incubations
The experiments were run as follows: 0.5 μ of test compound in DMSO or 0.5 μl DMSO alone was added to reaction tubes. 0.5 ml aliquots of the stirred PMN suspension maintained at 37° C. were then added. After 2 minutes, 0.5 μl of 10 mM A23187 (final concentration =10 μM) or 0.5 μl of DMSO was added and allowed to incubate for 4 additional minutes at 37° C. The reaction was stopped by the addition of 0.5 ml of cold methanol. The precipitated proteins were removed by centrifugation and the supernatant fluid was analyzed via RIA or HPLC.
Radioimmunoassay determinations of LTB 4
Radioimmunoassays were performed using the dextran-coated charcoal binding method as described by J. L. Humes in Methods for Stuyding Mononuclear Phagocytes (Eds. D. Adams et al.) p. 641, Academic Press, N.Y. (501).
Aliquots, 2 μl, of the supernatant fluids were added to assay tubes and incubated for 10 minutes at 37° C. to remove methanol. Fifty μl of tissue culture medium M-199 containing 1 percent heat-inactivated-porcine serum was then added to each tube. Standard amounts of LTB 4 were also prepared in this medium so that 50 μl aliquots contained 25-1000 pg Antisera to LTB 4 was diluted 1:3000 with 10 mM potassium phosphate, pH 7.3 containing 1 mM ethylenediaminetetracetic acid and 0.25 mM thimerasol (PET buffer). Aliquots, 100 μl of the diluted antisera were added to both standard and unknown tubes and incubated at room temperature for 0.5 hour. (5,6,8,9,11,12,14,15- 3 H)-LTB 4 (Amersham, 150 Ci/mMol) was diluted with PET to a concentration of 1 nCi/ml. Aliquots, 100 μl were added and the mixture incubated for 2 hours at room temperature or alternatively overnight at 4° C. One ml of dextrancoated charcoal solution is added to all tubes. After centrifugation for 10 minutes at 1000×g the radioactivity in the supernatant fluid was determined.
The dextran-coated charcoal removes the unbound 3 H-LTB 4 . Therefore in this procedure the antibody-bound- 3 H-LTB 4 is measured. The RIA 4 determinations are performed on single samples.
TABLE 3______________________________________Effect of Compounds of formula (I) on PMN-5-lipoxygenasePosition Dose %of N R X.sub.1 X.sub.2 mg/ml Inhibition______________________________________ ##STR23##5 (CO)CH.sub.3 4-CH.sub.3, 6-CH.sub.3 p-OCH.sub.3 0.3 75 0.1 45 0.03 47 (CO)CH.sub.3 H p-CF.sub.3 1 100 0.3 100 0.1 617 " H p-F 0.1 100 0.037 49 0.01 247 H H " 0.3 100 0.1 99 0.037 88 0.01 325 (CO)CH.sub.3 H p-OCH.sub.3 0.3 99 0.1 80 0.037 225 H 4-CH.sub.3, 6-CH.sub.3 H 1 99 0.3 90 0.1 436 H H p-OCH.sub.3 0.3 100 0.1 79 0.03 457 (CO)CH.sub.3 H o-OCH.sub.3 0.3 100 0.1 73 0.03 336 H 4-CH.sub.3, 6-CH.sub.3 p-OCH.sub.3 1 93 0.3 54 0.1 307 H H m-OCH.sub.3 0.3 100 0.1 100 0.03 767 (CO)CH.sub.3 H H 0.1 100 0.037 95 0.01 405 " H H 0.3 100 0.1 97 0.037 587 " H p-CN 0.3 100 0.1 77 0.037 395 " H p-OCH.sub.3 0.3 100 0.1 607 " H " 0.1 100 0.037 597 H H " 0.1 100 0.037 245 H H " 0.3 100 0.4 637 (CO)CH.sub.3 H m-OCH.sub.3 0.3 100 0.1 97 0.037 527 H H H 0.1 100 0.012 327 (CO)CH.sub.3 4-Cl H 1 100 0.1 32 0.037 227 (CO)CH.sub.3 H p-OCH.sub.3 0.1 100 0.037 707 (CO)CH.sub.3 6-Cl H 1 100 0.3 82 0.1 634 (CO)CH.sub.3 H p-OCH.sub.3 1 100 0.3 73 0.1 217 H t-Bu H 1 98 0.3 98 0.1 537 (CO)CH.sub.3 t-Bu H 0.03 23 1 95 0.3 70 0.1 34 ##STR24##7 H H H 1 98 0.3 94 0.1 39 0.03 07 (CO)CH.sub.3 H H 1 95 0.3 55 0.1 31 ##STR25##6 (CO)CH.sub.3 H 1 90 0.3 49 0.1 33______________________________________ | 3-Hydroxyazabenzo[b]thiophene derivatives having optionally 2-aryl, 2-aralkyl, 2-alkyl or 2-alkenyl substituents were prepared by, among other methods, ring closure of an appropriately substituted benzylthio-alkoxycarbonyl-pyridine. These compounds are found to be useful in the treatment of pain, fever, inflammation, arthritic conditions, asthma, allergic disorders, skin diseases such as psoriasis and atopic eczema, cardiovascular disorders, inflammatory diseases and other leukotriene mediated diseases. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to building panels for use in construction, and, in particular, to a composite, light-weight building panel for use as an exterior curtain wall panel in commercial exterior finish and insulation systems.
Exterior finish and insulation systems ("EFIS") for exterior walls have become increasingly popular in commercial construction as alternatives to brick, stone, metal, and wood facades. The EFIS system is characterized by a foam facing, expanded polystyrene or polyurethane, which is adhered to a support substrate. The foam facing is covered by a base coat of synthetic plaster and portland cement in which a fiberglass mesh is embedded. The base coat is covered by a finish coat of synthetic plaster. The finish coat may be applied with different textures in almost unlimited colors to provide a wide variety of aesthetic appearances.
EFIS wall systems may be constructed on-site or manufactured as panels which are brought to the site as completed components and attached to the building support structure. The most common type of panel using the EFIS systems uses a steel stud and gypsum framing wall as the substrate for mounting the foam facing. More particularly, a series of uniforms spaced metal studs are connected to metal channels at the top and bottom. Gypsum sheathing is attached to the studs by conventional fasteners. The foam facing is then adhered to the sheathing by adhesives and finished as described above.
The EFIS panel may incorporate additional batt insulation between the studs and the interior finished with dry wall or the like. These panels are less expensive than other facades, result in lower construction, installation and maintenance costs, and can reduce energy consumption. However, such panels have certain disadvantageous. Although lighter than solid stone panels and like facades, these panels are quite heavy. In large sizes the weight of the panel requires lifting devices such as cranes for hoisting the panel to the desired location on the building. Moreover, the insulating value of the panels is generally only R6-R8 unless batt insulation is installed between the studs which then provides and overall R-value of about 20. However, batt insulation is prone to sagging with an inconsistent insulating value over time. Perhaps, the biggest limitation of these panels is delamination of the foam and coatings at the foam-gypsum interface. This can readily occur where moisture is able to penetrate the sheathing and over time loosen the bond between the gypsum and foam deteriorates. As a result, there can be peeling of the coated foam or complete separation from the support frame.
To overcome the above delamination problems, another approach has utilized a large foam panel having vertical grooves into which opposed pairs of rectangular tubes were adhesively connected. The tubes are connected at the top and bottom to horizontal channels by fasteners. Because the base coat does not adhere tenaciously to steel, the tubes are covered by thin strips of foam. This can present problems in finishing the panel in that the strip must be level with the front coating surface to avoid seeing the strips after the coating is applied. This can require considerable finishing labor, primarily sanding or rasping of the surface to insure that all surfaces are level. Moreover, these strips must be securely attached to avoid possible delamination, but however form a lesser difficulty than the gypsum/foam delamination referred to above.
BRIEF SUMMARY OF THE INVENTION
The present invention overcomes the above limitations of the above EFIS panels by providing a foam composite panel having a continuous, level front surface, free of gypsum and seams, to which the coating may be applied. A foam core of expanded polystyrene carries the support steel in recessed grooves on the rear surface only. No steel penetrates the front surface of the foam. The tubes are evenly laterally spaced along the width of the core and fastened top and bottom to channels overlying the top and bottom surfaces. The tubes are open box type tubes with reverse inner flanges. The tubes are chemically bonded to the surfaces of the tube to establish a composite with the foam. The resultant panel is extremely strong in both wind loading and axial loading permitting the design to be used for both curtain wall and load bearing wall applications. Because of the expanded polystyrene core a high and consistent R-value is provide which at typical thickness is R-23 or greater. The weight of the panel is approximately 40% lighter than the metal stud/gypsum panels. Panelss may be assembled in side-by-side relationship to form light weight panel of desired length. In multiple core assemblies, the top and bottom channels are continuous and align the cores to present a minimum amount of foam finishing prior to coating.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and features of the present invention will become apparent upon reading the detailed description of the preferred embodiment taken in conjunction with the accompanying drawings in which:
FIG. 1 is a rear elevational view of a composite building panel in accordance with the present invention;
FIG. 2 is a cross sectional view of the panel taken along line 2--2 in FIG. 1;
FIG. 3 is a horizontal cross sectional view of the panel taken along line 3--3 in FIG. 1;
FIG. 4 is an enlarged cross sectional view taken along line 4--4 in FIG. 1;
FIG. 5 is a view similar to FIG. 4 with the horizontal channel removed;
FIG. 6 is an enlarged fragmentary cross sectional view taken along line 5--5 in FIG. 1;
FIG. 7 is a view similar to FIG. 5 with the vertical channel removed; and
FIG. 8 is a fragmentary perspective view of another embodiment of the panel shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, FIGS. 1-3 show a composite building panel 10 in accordance with the invention. The panel 10 as illustrated is substantially rectangular defined by transversely spaced front and rear walls 12 and 14, vertically spaced top and bottom walls 16 and 18, and laterally spaced end walls 20 and 22. However, it will become apparent that the panel is amenable to other configurations as defined by the peripheral walls, such as gabeled, crowned and like architectural treatment, particularly as applied to the top wall. More particularly, the panel 10 comprises a polymeric foam core 24, defined by the walls, which is structurally integrated with a plurality of vertical open-box tubes 26 to which an upper channel 28 and a lower channel 30 are attached by fasteners 34. As shown in FIG. 3, the panels and portions thereof may be assembled in side by side relationship with other panels 10A or 10B, or portions thereof to form an integrated panel of desired length.
As shown in FIG. 7, vertical grooves 36 are formed in the rear wall 14 of the core 24. Each groove 36 has a depth defined by a base wall 37, and a width defined by opposed side walls 38. The depth and a width of the grooves conform to the cross section of the vertical tubes 26. The grooves 36 may be formed by any conventional technique such as hot wire cutting or routing. The grooves 36 are uniformly spaced across the width of the core 24 to provice uniform on-center spacings for the tubes 26, typically 12 in., 16 in. and 24 in. As illustrated in FIG. 1, a 48 in. wide panel using 16 in. centers would have the tubes 8 in. from the side walls and one tube at the center. Thus, in assembly, the uniform tube spacing would be maintained.
As shown in FIG. 6, the vertical tube 26 in cross section is an open modified box tube configuration and preferably of the type disclosed in U.S. Pat. No. 4,037,379 granted on Jul. 26, 1977 to Leroy Ozanne. The tube 26 is defined by a base wall 40 coextensive and flush with the rear wall 12, a pair of rearwardly extending side walls 42 mating with the side walls 38 of the grooves 32, and inwardly turned flanges 44 adjacent the base 37 of the grooves 32. The side walls 42 of the vertical tubes 26 are structurally attached to the core 24 at the side walls of the grooves 36 by an adhesive 50. As a result the tube 26 is reinforced along its entire length, in compression by the compressive strength of the core 24 and in tension by the tensile strength of the core/adhesive bond. The resultant composite under loading is substantially greater than the strength of the tube itself. The tubes should have a depth to width ratio of about 1.5:1 or greater. A typical tube of 20 gauge galvanized steel would have a width of about 1.625 in., a depth of about 2.815 in., and flanges of about 0.438 in.
Referring to FIG. 5, the top wall 16 of the core 24 is provided with a horizontal slot 52 spaced from the rear wall 12 of the core 24 the width of the channel 28. The channel 28 has a base 54 which engages the top surface of the core 24 and a pair of depending legs 56 and 58. Leg 56 is received in slot 52 and adhered to the side walls thereof by adhesive 60. Leg 58 overlies the base 40 of the tube 26 and is attached thereto by suitable means such as self tapping fasteners 34, spot welding or other suitable means. The lower channel 30 is attached in a similar manner.
The core 24 is preferably an expanded polystyrene. Depending on the loading requirements for the panel, the density of the core 24 may range from 1#/c.f. to around 2#/c.f. The thickness of the core 24 may likewise vary in accordance with the application. Typically, the thickness would be around 4 in. to 6 in., however if architectural detailing is desired such as shown in FIG. 8, greater thicknesses may be provided. As to height, the panels may be virtually any height, and, if required, may be stacked end to end. Conventional manufacturing techniques for expanded polystyrene normally limit the width to around 48 in. Accordingly if a greater panel width is desired, the panels may be assembled side-by-side as shown in FIG. 3. Preferably, the upper and lower channels would span this assembled width in a single continuous piece. However multiple pieces can be used but each piece should span at least two panels.
The upper and lower channels 28, 30 are preferably conventional light gauge galvanized steel. Depending on the loading requirements, the thickness may range from around 12 gauge to about 24 gauge. Similarly, the vertical tubes 26 are light gauge galvanized steel of similar range of thicknesses.
The adhesive used for bonding the steel components to the core is a two part epoxy system. Suitable adhesives are Emecole Product No. X8-8-71 manufactured by Lucole Inc. or PlioGrip 7600 series manufactured by Ashland Chemical Co. Other adhesives may be beneficially employed. However any such adhesive should provide secure bonding between the core and the metal components and have a peel strength greater than the shear strength of the core.
The basic panel as described above is amenable to a variety of exterior and interior finishings. FIG. 8 illustrates a synthetic finished exterior curtain wall panel of the type employed as the exterior skin of a building spanning the spacings between widows doors and other architectural detailings. Therein, the panel 100 comprises an expanded polystyrene core 102 having chemically bonded thereto vertical tubes 104 (only one being illustrated) disposed in grooves 106 as described above. An upper channel 108 overlies the vertical tube 104 on the top surface of the core 102. The inner leg of the channel 108 is structurally attached to the base of the vertical tube 104 by fasteners 110. A lower channel 112 is similarly attached to the vertical tube 104 at the base of the core 102.
The front surface of the core 102 is provided with a horizontal architectural reveal 114 which may be formed by conventional techniques. The front surface of the core 102 is clad with a conventional synthetic coating 120 comprising a cement acyrlic base coat 122, a glass fiber reinforcing mesh 124 embedded in the base coat 122, and an acrylic finish coat overlying the base coat 122. Dry wall sheeting 128 is applied to the inner face of the core 102 and attached to the vertical tubes 104 by dry wall screws (not shown). Examples of other exterior finishes which may be applied include metal cladding, ceramic tiling, wood, vinyl or any other treatment customarily used in building construction. As a typical attachment to the building framing (not shown), the panel 100 may be attached at the vertical tubes 104, by welding or fasteners, to a horizontal beam 130 structurally attached to the building, and may be additionally supported by bracing 132. Any other conventional connections may likewise be used on the steel components.
Various modifications of the above-described embodiment will become apparent to those skilled in the art. Accordingly, the scope of the invention is defined only by the accompanying claims. | A composite building panel includes a core of a foamed polymeric insulating material, such as expanded polystyrene, having a plurality of uniformly spaced open box tubes retained in vertical grooves formed in the rear surface of the core by a two-part epoxy adhesive, the tubes being mechanically connected at their ends to one leg of continuousa horizontal channels having their other leg adhesively secured to the core at horizontal slots. The front surface of the core is continuous without seams and may be coated with a variety of exterior insulation finishing system coatings. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is based upon and claims the benefit of priority from the prior Japanese Patent Applications No. 2001-157792, filed on May 25, 2001; the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention belongs to the field of wireless communication systems making use of wireless communication links and, particularly, relates to an interference detection method and an interference avoidance system for detecting interference with another wireless communication device and effectively avoiding the interference.
2. Description of the Related Art
Conventionally, there are employed, as a technique for avoiding interference with another system, the use of a filter for preventing interference with frequency bands which are not used in its own system, and the provision of a sufficient spatial interval between both systems for preventing interference with each other.
Because of this, when frequency bands are determined for use in the respective wireless communication systems within the same area in the case of the prior art techniques, there are provided guard-band intervals with which radio waves can be sufficiently attenuated by the use of a filter and the like for the purpose of preventing generation of unnecessary signals.
Also, the carrier sense access has been generally used as a technique for avoiding interference in the frequency bands of its own system by receiving radio waves in the frequency band which will be used for signal transmission and the frequency band which will be used for signal reception, in advance of actually transmitting radio frequency signals in the frequency band as predetermined for use in its own system, in order to confirm that there is no other signals which would interfere with its own system and vice versa.
There are a variety of implementations of the carrier sense access depending on the wireless communication systems as used. TDMA-TDD (Time Division Multiple Access Time—Division Duplex) will be explained as one example of the system which is being employed in PHS (Personal Handy Phone System in Japan) and the like and in which the same frequency is time divided for signal transmission and for signal reception.
In the case of TDMA-TDD, a single frequency carrier is timely divided into a plurality of time slices. The respective slices are called as time slots. Furthermore, which of the downlink used by a wireless base station for signal transmission and the uplink used by the wireless base station for signal reception is determined for each time slot. For example, in the case of PHS as described above, 5 ms is divided into eight time slots in order that each successive four time slots are assigned to the uplink channel and the downlink channel in turn.
Also, in the case of TDMA-TDD, a plurality of frequencies are available so that each wireless communication link for use is defined by combination of frequencies and time slots of 5 every ms. In the case of making use of a wireless communication link, a wireless communication device such as a wireless base station receives, in advance of actual signal transmission, a time slot for use in correspondence with the frequency of the wireless communication link for use and the time as predetermined for use in order to confirm that the received signal level of the wireless communication link is no higher than a predetermined level.
In this case, however, if a signal higher than the predetermined level is received via the communication link as predetermined for use, the wireless communication link is changed to another wireless communication link followed by repeating signal reception. This procedure is repeated until such a wireless communication link is found as the signal received level is no higher than the predetermined level, and then it becomes possible to make use of the wireless communication link without fear of interference.
Also, if there occurs anew interference with another wireless communication device, for example, in the case of a mobile communication while a mobile wireless communication device (referred to as a mobile terminal in the following description) moves, it is possible to detect the deterioration of the communication link quality by monitoring the data error rate and to initiate “channel switching” by switching the wireless communication link to another wireless communication link free from interference in order to avoid interference.
On the other hand, in accordance with an interference detection mechanism in a wireless communication device of the TDMA-TDD system, it is possible to measure signal levels for the respective “frequencies (carrier numbers)” and the respective “times (the time slots)” as illustrated in FIG. 3 by making use of a wireless communication device equivalent to that for use in communication and available time slots other than time slots for current use in communication in order to measure the received signal level for each frequency and each time slot.
However, in the case where there are two different wireless communication systems in the same area, it is necessary to distinguish the frequencies for use from one another and to provide a guard-band interval between the respective systems. On the other hand, from the view point of making effective use of the frequency resource, there is a need for setting the guard-band interval as narrower as possible,
However, for example, in the case where the frequency resource is allocated on the basis of an international scheme, it may be the case that sufficient guard-band intervals can not be provided between an existing domestic system and a new international system. In the case where a filter is used to attenuate radio waves outside of its own frequency band, the size of the filter as required becomes large in the case where the guard-band interval is decreased while it is difficult to sufficiently attenuate radio waves outside of its own frequency band in the case where a filter is used for this purpose.
However, since it is not always possible to identify the location of the wireless communication device which may suffer from interference, ample guard-band intervals are provided, even if there is entirely no interference in most locations, for the purpose of avoiding interference which would take place when two wireless communication stations are located close to each other, resulting in ineffective utilization of the frequency resource.
In order to solve the shortcomings, if variable guard-band intervals are used in the individual areas and between the respective systems in which interference may become problematic instead of the use of the same width of the guard-band intervals for all of the areas, there arises another problem that the wireless communication equipments of two different systems can not be installed independent from each other.
Practically speaking, it is difficult to individually control a number of wireless communication equipments and to individually limit the use of a problematic band. Meanwhile, it is possible to avoid interference by detecting interfering waves in the frequency for use in advance of actually making use of a wireless communication link in accordance with the carrier sense access as described above as a prior art technique. However, in the case where there is interference by spurious components as transmitted from a wireless communication device of an adjacent system and spread over a wide frequency range, interference is detected over the wide frequency range as illustrated in FIG. 2 when the carrier sense access described above as a prior art technique is used, so that there is a problem that a substantial time is needed to search an available frequency in practice.
In the following description, conventional problems will be explained with the interference detection method in the case of a public PHS base station equipment as an example. In this example as illustrated in FIG. 2 , a wireless communication system A is a PHS while a wireless communication system B is an IMT-2000 system. There is a guard-band interval of about 5 MHz between these two systems. Also, the frequency band of the IMT-2000 system closest to the frequency bands of the PHS is used to transmit signals from a mobile terminal to the base station equipment.
In usual cases, radio waves outside of the frequency band due to transmission signals B 1 from the wireless communication device of the wireless communication system B is sufficiently suppressed within the guard-band interval by the use of a filter and the like in order not to cause interference with the wireless communication system A. However, in the case where the wireless communication devices of both systems are located very close to each other, radio waves from the transmission signal B 1 outside of the frequency band affects the system A as broad band interference.
The signals of the IMT-2000 system are timely continuous and have broad spectrum as compared with the PHS. The signals of the PHS are transmitted as frames each of which consists of eight time slots by time division of the frequencies of the respective carrier numbers distant from each other with 300 KHz. In the base station equipments of the PHS, since the carrier numbers and the time slots for use are dynamically assigned to the respective mobile stations by each base station equipment, the carrier sense access procedure is performed in advance of actual signal transmission, when the wireless communication link is used, in order to confirm that there is no signal in the frequency of the carrier number for use and the time slot for use.
However, in the case posed here as problematic, i.e., where there are interfering signals spread over a wide frequency area (over a plurality of carrier numbers), it is possible to detect interference for the respective time slots but not possible to distinguish the interference from each signal transmitted in a narrow frequency band in accordance with time division multiplexing for effectively avoiding the interference.
Accordingly, it is an object of the present invention to solve the problem as described above and to provide a method and a wireless communication device in which, in the case where two wireless communication systems are located close to each other and possibly interfere with each other, it is possible to detect if broad band interference takes place, and, when broad band interference takes place, to limit the use of frequencies within such a frequency range in which the wireless communication systems are little affected by the interference, and therefore to automatically and effectively avoid interference, resulting in a narrower guard-band interval effective between the two systems.
BRIEF SUMMARY OF THE INVENTION
The present invention has been made in order to solve the shortcomings as described above and is characterized by, when interference between one system and another system is detected in a wireless communication making use of frequency division multiplexing, measuring a received signal level for each of frequencies corresponding to carrier numbers in the one system; storing the received signal levels as measured in association with the respective carrier numbers; generating a measured level group from each (called “selected carrier number” here) of carrier numbers which are selected one after another and a plurality of carrier numbers adjacent to said each of selected carrier numbers, performing an arithmetic operation of each of the respective measured level groups, and storing each result of the arithmetic operation in association with the selected carrier number; comparing the results of the arithmetic operation as stored corresponding to the respective carrier numbers with a predetermined interference threshold level; and storing each comparison results in association with the selected carrier number.
In accordance with the present invention, interfering signals can be detected by generating a measured level group for each carrier number for use in its own system including the carrier numbers adjacent to said each carrier number, calculating a delineative level of each measured level group (the minimum level, the average level, a representative level and so forth), and therefore exceptional levels (for example, an abnormal signal level which appears only with a particular carrier number) can be removed in advance of the detection. As a result, it is possible to extract only interfering signals which are continuously generated over a wide range of frequencies.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a block diagram showing the basic configuration of an interference avoidance system in accordance with the present embodiment.
FIG. 2 is a graphic diagram showing an example of interference between a wireless communication system A (the system of the present invention) and a wireless communication system B (another system).
FIG. 3 is a graphic diagram for explaining unit blocks of measuring signal levels in a wireless communication making use of frequency division multiplexing and time division multiplexing.
FIG. 4 is a graphic diagram showing exemplary signal levels of only narrow band interfering signal in accordance with time multiplexing.
FIG. 5 is a graphic diagram showing exemplary signal levels of only broad band and time independent interfering signals.
FIG. 6 is a graphic diagram showing the levels of the interfering signal as combined.
FIG. 7 is a graphic diagram showing resultant data after obtaining minimum signal levels from adjacent m carriers.
FIG. 8 is a graphic diagram showing the interfering signal levels as detected of the broad band and time independent interfering signals.
FIG. 9 is a flowchart showing the procedure for a first embodiment of the present invention.
FIG. 10 is an explanatory view for schematically showing the arithmetic operation in the first embodiment.
FIG. 11 is a flowchart showing the procedure for a second embodiment of the present invention.
FIG. 12 is an explanatory view for schematically showing the arithmetic operation in the second embodiment.
FIG. 13 is a flowchart showing the procedure for a third embodiment of the present invention.
FIG. 14 is an explanatory view for schematically showing the arithmetic operation in the third embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[First Embodiment]
(The Overall Configuration of the Interference Avoidance System)
In the following description, an interference avoidance system in accordance with a first embodiment of the present invention will be explained. FIG. 1 is a block diagram schematically showing the basic configuration of the interference avoidance system in accordance with the present embodiment.
The interference avoidance system in accordance with the present embodiment is composed of a communication link controlling unit 1 , a carrier number designation unit 2 , a time slot designation unit 3 , a radio frequency signal transmitting unit 4 , a radio frequency signal receiving unit 5 , a calculation result storing unit 6 , a carrier number storing unit 7 , a threshold level comparing unit 8 , a signal level storing unit 9 and a threshold level storing unit 10 as illustrated in the same figure.
The communication link controlling unit 1 controls the communication links for use in communication by the radio frequency signal transmitting unit 4 and the radio frequency signal receiving unit 5 , and input control signals to the carrier number designation unit 2 and the time slot designation unit 3 to designate the carrier numbers and the time slots to be used by the radio frequency signal transmitting unit 4 and the radio frequency signal receiving unit 5 .
The carrier number designation unit 2 serves to designate the carrier numbers for signal reception and transmission by the radio frequency signal transmitting unit 4 and the radio frequency signal receiving unit 5 on the basis of the control signal as input from the communication link controlling unit 1 . Also, the carrier number designation unit 2 serves to output the carrier number, which is assigned to the radio frequency signal receiving unit 5 , to the signal level storing unit 9 and the calculation result storing unit 6 .
The time slot designation unit 3 serves to designate the time slot numbers used by the radio frequency signal transmitting unit 4 and the radio frequency signal receiving unit 5 for signal transmission and reception on the basis of the control signals as input from the communication link controlling unit 1 . Also, the time slot designation unit 3 outputs the time slot number, which is assigned to the radio frequency signal receiving unit 5 , to the signal level storing unit 9 and the calculation result storing unit 6 .
The radio frequency signal transmitting unit 4 is a signal transmission means for transmitting radio waves to the base station during wireless communication to perform transmission of signals by the use of the frequency and the time slot as designated by the carrier number designation unit 2 and the time slot designation unit 3 . The radio frequency signal receiving unit 5 is a signal reception means for receiving radio waves from the base station during wireless communication to perform reception of signals by the use of the frequency and the time slot as designated by the carrier number designation unit 2 and the time slot designation unit 3 . Also, the radio frequency signal receiving unit 5 in accordance with the present embodiment has a function of measuring the signal levels of the radio frequency signals as received and outputting measurement results to the signal level storing unit 9 .
Meanwhile, generally speaking, a plurality of signal receiving units are required for receiving radio frequency signals of different carrier numbers at the same time. However, since the time slot number is repeated for each frame period in the case of a wireless communication link in accordance with time division multiplexing, radio frequency signals are received while the carrier number is changed for each the frame cycle to measure the received signal levels corresponding to different carrier numbers of the same time slot number by means of a single signal receiving unit.
Also, it is possible with the radio frequency signal receiving unit 5 to measure all of the slots by temporarily receiving necessary slots and switching the signal transmission link to another slot while the current signal transmission with the carrier number and the time slot number being for use is suspended without affecting the communication. By this configuration, in accordance with the present embodiment, the signal transmitting and receiving unit for communication serves both as a signal receiving unit for communication and as a signal receiving unit for measuring signal levels rather than providing a separate signal receiving unit.
The signal level storing unit 9 serves to store the levels of signals as measured by the radio frequency signal receiving unit 5 in association with the carrier numbers and the time slot numbers corresponding to the respective signals. This signal level storing unit 9 provides array variables M consisting of n*Ft elements, wherein n is the number of all the carriers and Ft is the number of the time slots per frame, and stores the received signal level Si,t corresponding to the carrier number i and the time slot number t in the array variable element M(i,t). FIG. 3 shows the arrangement of time slots as unit boxes of measurement in which the respective elements of the array variables M correspond to the respective boxes.
The calculation result storing unit 6 reads out the respective received signal levels stored in the signal level storing unit 9 , performs an arithmetic operation on the basis of the levels corresponding to a plurality of the carrier numbers adjacent to each carrier number and stores the results of the operation in association with the carrier numbers. Also, the calculation result storing unit 6 in accordance with the present embodiment serves to perform an arithmetic operation of the respective received signal levels for each carrier number on the basis of the levels corresponding to the time slot numbers within a predetermined range and store the results of the operation in association with the respective carrier numbers.
The arithmetic operation performed by the calculation result storing unit 6 is such as to generate a measured level group from each carrier number and a plurality of carrier numbers adjacent thereto, and to obtain the minimum level for each measured level group. Meanwhile, other possible arithmetic operations to be performed by the calculation result storing unit 6 are such as to obtain the average level from each measured level group and to determine a representative level selected from each measured level group in accordance with majority decision.
The threshold level storing unit 10 serves to store, as a threshold level, the signal level at which interference occurs. The threshold level is used to determine, in correspondence with the type of the arithmetic operation to be performed by the calculation result storing unit 6 , the range of the signal level in which interference occurs and may be experimentally obtained or theoretically calculated.
Also, the threshold level comparing unit 8 reads out the threshold level stored in the threshold level storing unit 10 , extracts the carrier numbers corresponding to the signal levels (the result of the operation) within the range determined by the threshold level (for example, the signal levels exceeding or falling under the threshold level) by comparing the threshold level as read with the result of the operation received from the calculation result storing unit 6 , and then outputs the carrier numbers as extracted to the carrier number storing unit 7 .
The carrier number storing unit 7 serves to store the carrier numbers which are obtained by comparison with the threshold level by means of the threshold level comparing unit 8 , and output the carrier numbers as stored to the communication link controlling unit 1 . The communication link controlling unit 1 serves to select a carrier number for use with reference to the carrier numbers obtained from the carrier number storing unit 7 .
(Interference Detection Method in the Interference Avoidance System)
Next, the basic mechanism of the interference detection method in the interference avoidance system having the configuration as described above will be explained. Meanwhile, in the case of the present embodiment, it is assumed that its own system is based on a narrow band and time division system such as a PHS while another system is based on a broad band and frequency division system. Also, it is assumed that the interfering signal level of the narrow band and time division system is higher than the interfering signal level of the broad band and frequency division system.
If the interfering signals are composed only of narrow band and time division signals generated from its own system, the data as stored in the signal level storing unit 9 is as illustrated in FIG. 4 . In this case, as illustrated in the same figure, the signal levels appear cyclical for a short time, e.g., for several tens of frames (the frame period is usually in the order of 10 ms). in the order of On the other hand, if the interfering signals are composed only of broad band signals which are generated from another system and have no timely correlation, the signal levels are as illustrated in FIG. 5 .
However, in the actual case, the transmitted signals as illustrated in FIG. 4 and the interfering signals as illustrated in FIG. 5 are received at the same time and added together so that the data as stored in the signal level storing unit 9 is as illustrated in FIG. 6 .
Since the signals of both systems are mixed in this configuration, it is impossible to recognize the existence of the broad band interfering signals. However, by performing selection of the minimum level among from the signal levels stored in a plurality of storage elements of the signal level storing unit 9 , it is possible to presume and detect the existence of the broad band low level interfering signals.
The selection of minimum levels is implemented, for example, by {circle around (1)} generating a measured level group consisting of a plurality of adjacent carrier numbers an obtaining a minimum level from the measured level group, {circle around (2)} generating a measured level group consisting of all of the time slots belonging to one carrier number and obtaining a minimum level from the measured level group, {circle around (3)} generating a measured level group consisting of all of the time slots belonging to a plurality of adjacent carrier numbers and obtaining a minimum level from the measured level group, and {circle around (4)} generating a measured level group consisting of a predetermined number of the time slots belonging to a plurality of adjacent carrier numbers and obtaining a minimum level from a measured level group.
Meanwhile, in the case of the present embodiment, the method of obtaining a minimum level from the respective time slots (the above described {circle around (2)}), and the method of obtaining a minimum level from a plurality of adjacent carrier numbers (the above described {circle around (3)}) will be explained.
As an example of the collection of the minimum levels as obtained, FIG. 7 shows data as stored in the calculation result storing unit 6 after obtaining minimum signal levels from measured level groups each of which is generated from a carrier number and a pair of carrier numbers adjacent thereto on the basis of the interfering signals as illustrated in FIG. 6 .
Then, from the configuration of FIG. 7 , the minimum level of all of the time slots belonging to each frequency is obtained as illustrated in FIG. 8 . As a result, the interfering signal level distribution which is independent of time as illustrated in FIG. 5 is reconstructed. It is possible to determine a frequency band susceptible to interference by comparing the signal levels of the respective signals as illustrated in FIG. 8 with the interference threshold level stored in advance.
Meanwhile, while the interfering signals monotone increasing toward the edge of the system band is used as an example for explanation in this description, it is possible in accordance with the present invention to detect broad band and time independent interfering signals within any frequency band used in the system A ( FIG. 2 ). Also, while FIG. 4 to FIG. 7 are illustrated such that the number of carriers n=20 and the number of time slots per frame Ft=8, the present invention is not limited thereto.
(Link Controlling Method in the Communication System)
A link controlling method using the communication system as described above will be explained in the following description. FIG. 9 is a flowchart showing the procedure of the link controlling method in accordance with the present embodiment. FIG. 10 is a schematic representation showing the procedure of an arithmetic operation in accordance with the present embodiment. In the case of the present embodiment, the signal level storing unit 9 and the calculation result storing unit 6 are represented respectively by two-dimensional array variables M(i,t) associated with the carrier number i and the time slot number t and one-dimensional array variables K(i) associated only with the carrier number i.
First, as illustrated in FIG. 9 , the signal levels Si,t are measured of all the time slot (t) belonging to each carrier number (i: 1≦i≦n), and stored in the storage elements M(i,t) of the signal level storing unit 9 in the step 101 .
Next, the measured levels stored in the storage elements within a predetermined range, as a measured level group, are subjected to the arithmetic operation, followed by storing the result of the operation in the calculation result storing unit 6 in the step 102 . More specifically speaking, for each carrier number (i), a measured level group G 1 is generated from all of the time slots (each time slot number u thereof satisfies u: 1≦u≦Ft) of the carrier number (i) and previous m and subsequent m carriers as illustrated in FIG. 10 , followed by obtaining the minimum level from (2m+1)×u measured levels included in each measured level group G 1 . Namely, each element K(i) of the array K for the respective i satisfying m+1≦i≦n−m is used to store the minimum level selected among from the levels M(j,u) of all the time slots belonging to the carrier number j satisfying i−m≦j≦i+m.
Next, the respective element K(i) (where m+1≦i≦n−m) is compared with the threshold level for limiting the carrier numbers available for use in the step 103 as a process A. More specifically explaining, in the process A, it is judged which of the respective element K(i) and the threshold level stored in the threshold level storing unit 10 is larger than the other in the step 104 . If the element K(i) is larger than the interference threshold level p, the carrier number is stored in the carrier number storing unit 7 while the use of the carrier number is restricted in the communication link controlling unit 1 in the step 105 . Contrary to this, if K(i)≦p in the step 104 , the restriction of the use of the carrier number i is removed in the step 106 .
Thereafter, the use of the carrier numbers 1 to m is restricted in accordance with the result of judgment relating to the carrier number m+1 in the step 107 to the step 109 while the use of the carrier numbers n−m+1 to n is restricted in accordance with the result of judgment relating to the carrier number n−m in the step 110 to the step 112 .
Meanwhile, while the frequency of judging interference is not specifically described in the present embodiment, it is possible to limit the use of the frequencies only at the time when interference is actually problematic, even in the case where interference does not always adversely exist, by judging broad band interference each time with such an interval during which averaging a plurality of frames and measuring the signal levels of all of the carrier numbers can be completed with a margin of safety.
In a simplified embodiment, when the minimum level K(i) is larger than the threshold level, the carrier number for use is selected among from other than the carrier number i, while the minimum level K(i) is not larger than the threshold level, the carrier number i can be used as the carrier number for use. Alternatively, the judgment result of comparing the minimum level K(i) with the threshold level is used as part of information available for selecting the carrier number for use.
[Second Embodiment]
Next, the second embodiment of the present invention will be explained. In the case of the second embodiment, the present invention is applied to another exemplary case where the wireless communication system A as illustrated in FIG. 2 is not based on time division multiplexing. In this case, while the ability of detecting interference is somewhat inferior to that of the first embodiment, the configuration thereof can be simplified. FIG. 11 is a flowchart showing the procedure of the interference detection method in accordance with the second embodiment of the present invention. FIG. 12 is a schematic representation showing the procedure of the arithmetic operation in accordance with the present embodiment. Meanwhile, in this case of the second embodiment, the time slot designation unit 3 can be dispensed with in the basic configuration ( FIG. 1 ).
First, as illustrated in FIG. 11 , the signal level Si is measured of each carrier number (i: 1≦i≦n), and stored in the storage elements M(i) of the signal level storing unit 9 in the step 201 .
Next, the measured levels stored in the storage elements within a predetermined range, as a measured level group, are subjected to the arithmetic operation followed by storing the result of the operation in the calculation result storing unit 6 in the step 202 . More specifically speaking, for each carrier number (i), a measured level group G 2 is generated from the carrier number (i) and previous m and subsequent m carrier numbers as illustrated in FIG. 12 , followed by obtaining the minimum level from (2m+1) measured levels included in each measured level group G 2 . Namely, each element K(i) of the array K for the respective i satisfying m+1≦i≦n−m is used to store the minimum level M(j) selected among from the levels of the measured level group G 2 in the calculation result storing unit 6 as K(i).
Accordingly, in the case of the present embodiment, the signal level storing unit 9 and the calculation result storing unit 6 are represented respectively by one-dimensional array variables M(i) and one-dimensional array variables K(i), both being associated only with the carrier number i.
Next, the respective element K(i) (where m+1≦i≦n−m) is compared with the threshold level for limiting the carrier numbers available for use in the step 203 as a process A. More specifically explaining, in the process A, it is judged which of the respective element K(i) and the threshold level stored in the threshold level storing unit 10 is larger than the other in the step 204 . If the element K(i) is larger than the interference threshold level p, the carrier number is stored in the carrier number storing unit 7 while the use of the carrier number is restricted in the communication link controlling unit 1 in the step 205 . Contrary to this, if K(i)≦p in the step 204 , the restriction of the use of the carrier number i is removed in the step 206 .
Thereafter, the use of the carrier numbers 1 to m is restricted in accordance with the result of judgment relating to the carrier number m+1 in the step 207 to the step 209 while the use of the carrier numbers n−m+1 to n is restricted in accordance with the result of judgment relating to the carrier number n−m in the step 210 to the step 212 .
[Third Embodiment]
Next, the third embodiment of the present invention will be explained. FIG. 13 is a flowchart showing the procedure of the interference detection system in accordance with the present embodiment. FIG. 14 is a schematic representation showing the procedure of the arithmetic operation in accordance with the present embodiment. This embodiment is effective also when time sharing signals are used also in the wireless communication system B ( FIG. 2 ) which is another system, in the situation of the first embodiment. The present embodiment is distinguished from the first embodiment as described above by the details of selecting minimum levels in which a minimum level is obtained from a predetermined number (plural) of time slots rather than all of the time slots.
In the case of the present embodiment, the signal level storing unit and the calculation result storing unit 6 are represented respectively by two-dimensional array variables M(i,t) associated with the carrier number i and the time slot number t and two-dimensional array variables K(i,t) associated also with the carrier number i and the time slot number t.
First, as illustrated in FIG. 13 , the signal levels Si,t are measured of all the time slot (t) belonging to each carrier number (i: 1≦i≦n), and stored in the storage elements M(i,t) of the signal level storing unit 9 in the step 301 .
Next, the measured levels stored in the storage elements within a predetermined range, as a measured level group, are subjected to the arithmetic operation followed by storing the result of the operation in the calculation result storing unit 6 in the step 302 . More specifically speaking, for each carrier number (i), a measured level group G 3 is generated from the time slots (each time slot number u thereof satisfies ((t−q) mod Ft)+1≦u≦((t+q) mod Ft)+1) of the carrier number (i) and previous m and subsequent m carriers as illustrated in FIG. 14 , followed by obtaining the minimum level from (2m+1)×u measured levels.
Namely, each element K(i,t) of the array K for the respective i satisfying m+1≦i≦n−m and 1≦t≦Ft is used to store the minimum level selected among from the levels M(j,u) included in the measured level group G 3 which consists of the time slots satisfying i−m≦j≦i+m and ((t−q) mod Ft)+1≦u≦((t+q) mod Ft)+1, wherein n is the number of all the carriers and Ft is the number of the time slots per frame as measured.
Next, the respective element K(i) (where m+1≦i≦n−m) is compared with the threshold level for limiting the carrier numbers available for use in the step 303 as a process B. More specifically explaining, in the process B, it is judged which of the respective element K(i) and the threshold level stored in the threshold level storing unit 10 is larger than the other in the step 304 . If the element K(i) is larger than the interference threshold level p, the carrier number is stored in the carrier number storing unit 7 while the use of the carrier number is restricted in the communication link controlling unit 1 in the step 305 . Contrary to this, if K(i)≦p in the step 304 , the restriction of the use of the carrier number i is removed in the step 306 .
Thereafter, the use of the carrier numbers 1 to m is restricted in accordance with the result of judgment relating to the carrier number m+1 in the step 307 to the step 309 while the use of the carrier numbers n−m+1 to n is restricted in accordance with the result of judgment relating to the carrier number n−m in the step 310 to the step 312 .
Meanwhile, in the case of in the present embodiment, the number Ft of the time slots per measurement period is preferably determined also with reference to the frame frequency Fb of the wireless communication system B in addition to the frame frequency Fa of the wireless communication system A, for example, on the basis of the least common multiple of Fa and Fb.
As explained above, in accordance with the present invention, it is possible to detect broad band interfering signals transmitted from another system, which signals had not easily been separated in accordance with in the prior art technique, by the use of the signal receiving unit of its own system, and therefore becomes possible to automatically limit the use of the communication link in which interference is detected and to automatically remove the limitation of the communication link when the interference disappears, resulting in an effective interference avoiding mechanism. Furthermore, in accordance with the present invention, it is also possible to reduce the fixed guard-band interval between adjacent two wireless communication systems, to adaptively secure a frequency band equivalent to a necessary guard-band interval, and therefore to provide a link controlling method and a wireless communication device in which effective use of the frequency resource is possible maintaining the freedom of designing and installing the two wireless communication systems,
The foregoing description of preferred embodiments has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described, and obviously many modifications and variations are possible in light of the above teaching. The embodiment was chosen in order to explain most clearly the principles of the invention and its practical application thereby to enable others in the art to utilize most effectively the invention in various embodiments and with various modifications as are suited to the particular use contemplated. | In the case where two wireless communication systems are located close to each other and possibly interfere with each other, it is detected if broad band interference takes place, and, when broad band interference takes place, the use of frequencies is limited within such a frequency range in which the wireless communication systems are little affected by the interference. An interference detection system for detecting interference between one system and another system in a wireless communication making use of frequency division multiplexing is described. The interference detection system includes a radio frequency signal receiving unit; a signal level storing unit; a calculation result storing unit; a threshold level comparing unit; and a carrier number storing unit. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 12/611,354, entitled “HANDS FREE MEASURING INSTRUMENT”, filed Nov. 3, 2009 by Louis A. Norelli, which claims the benefit of priority to U.S. Provisional Application Ser. No. 61/112,903 entitled “PLATFORM RULER”, filed Nov. 10, 2008 by Louis A. Norelli, the entirety of each being hereby incorporated by reference herein for all purposes.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates to measuring instruments, and more particularly, to an instrument for assisting in the process of plumbing, leveling, or making straight any individual or interconnected objects of any shape for use by builders, carpenters, iron workers, masons, and other tradespersons.
[0004] 2. Background of Related Art
[0005] The ruler, extension ruler, and tape measure are among the most commonly used measuring devices in the construction field. These measuring devices can also act as a guide or a gauge when building to plumb, level or straight is required. When undertaking a construction project, these qualities are essential to providing a professional and accurate product. This demand for accuracy creates challenges for a builder.
[0006] Different methods may be used by a builder to achieve plumb, level, and straight. When building to plumb or level, a builder can use a bubble level to fulfill these requirements. A bubble level's accuracy may be diminished by the length of the level relative to the length or size of the project being built. When a long horizontal span is required, the builder may use a dry line or laser to achieve better accuracy. For a vertical application, a plumb bob line or laser may used for better accuracy.
[0007] A useful skill in building to these requirements is the ability to fasten or secure material precisely and consistently. When setting up material to be fastened or secured, adjustments often need to be made to the material. However, when adjusting the material, a builder may often place the measuring device back in a tool belt, or otherwise put the measuring device aside, so that one or both hands can be used to adjust the building material. Occasionally, one hand can adjust material while the other hand holds the measuring device. When the desired dimension is found, both hands again may need to be freed to perform the fastening process. Consequently, a carpenter may be unable to assess or monitor the corresponding measurement until after the material is fastened or secured. Once the material is fastened or secured, the measurement will be checked again to ensure that the material did not move while fastening or securing the material. If the material moved during the fastening process, the fastening must be undone and the process repeated. This same procedure is needed not only for vertical applications, but for horizontal, levels and straights as well.
SUMMARY
[0008] The present disclosure is directed to a measuring instrument adapted to facilitate hands-free measuring in one or more (e.g., upright, horizontal or upsidedown) orientations. In one envisioned embodiment, the disclosed instrument includes a base, and a body projecting orthogonally therefrom. The instrument may include ruler graduations, one or more bubble level vials, one or more notches adapted to operably engage a line (e.g., string) and/or one or more pilot holes. In an embodiment, the disclosed instrument includes one or more magnets to facilitate the mounting thereof on ferrous material. A spring-loaded spike assembly may be included in the instrument to facilitate the mounting thereof on wooden material, on gypsum-based materials (e.g., wallboard such as Sheetrock®, manufactured by USG Corporation of Chicago, Ill., United States), on composite materials (e.g., polymer-based materials such as Trex®, manufactured by Trex Company of Winchester, Va., United States), and the like.
[0009] The disclosed instrument may provide utility for many different purposes, including without limitation, measuring, leveling, and squaring material. It is contemplated that an instrument in accordance with the present disclosure may be fixed in place temporarily, which may enable a builder to adjust material to its desired position, distance, and/or orientation, and fasten the material at the same time in a “hands-free” manner. It may remain in place to confirm that the fastening process was accurate.
[0010] The base may be adapted for particular purposes. For example and without limitation, the base may be magnetized which may be useful when a builder is framing metal studs or metal door frames. The disclosed device may enable a carpenter to take vertical readings without manually holding the measuring device. The disclosed device may be positioned vertically for horizontal reading, either right side up or upside down, as is typically required when constructing fascias, soffits, or free standing walls. Metal track (e.g., suspended ceilings) can be lowered or raised to the corresponding dimensions established by the builder, with the use of a dry line or a laser line.
[0011] The base of the disclosed instrument may include a screw or other threaded means for attaching to wood, and/or may include a suction device (e.g., a suction cup) for attaching the base to glass or non-magnetic metals (e.g., aluminum). The base may provide a balanced and sturdy mounting that is well-adapted to the leveling of concrete (“mud”) floors, subfloors and raised flooring, e.g., computer room floors.
[0012] In an embodiment, the disclosed hands-free measuring instrument includes a base member having a top surface and a bottom surface. An upright member is coupled to the top surface base and extends orthogonally (e.g., at a right angle) therefrom. A first magnet may be disposed on a bottom surface of the base member to enable the instrument to be magnetically secured to a ferrous workpiece. A second magnet may additionally or alternatively be disposed on a vertical edge of the upright member. The instrument includes at least one bubble level vial disposed on the instrument, and may include one bubble level disposed horizontally on the base member, and/or one bubble level disposed vertically on the upright member.
[0013] In embodiments, a spike assembly may be disposed within the instrument that is adapted to mechanically secure the measuring instrument to a workpiece. The spike assembly may include a shaft slidably disposed within the upright member. A top end of the shaft may extend upwardly beyond a top surface of the upright member. The bottom end of the shaft may include a spike tip coupled thereto. The shaft includes at least one stop member configured to limit upward and/or downward travel of the shaft.
[0014] In another embodiment in accordance with the present disclosure, a hands-free measuring instrument includes a base member having a top surface and a bottom surface, and a first magnet disposed on a bottom surface of the base member and configured to secure the measuring instrument to a workpiece. The instrument includes an upright member coupled to the top surface base and extending orthogonally therefrom, and a second magnet disposed on a vertical edge of the upright member and configured to secure the measuring instrument to a workpiece. The measuring instrument includes an adjustable ruler arm rotatable around a pivot adjacent to a top surface of the upright member. The pivot may be configured to selectively retain the adjustable ruler arm in a fixed position. At least one of the upright member or the adjustable ruler arm includes one or more detents configured to index the adjustable ruler arm to a predetermined position. The upright member may include a one or more angular graduations disposed on a face of the upright member. The one or more angular graduations may be numerated to indicate the angle at which the adjustable ruler arm is positioned relative to the upright member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The above and other aspects, features, and advantages of the present disclosure will become more apparent in light of the following detailed description when taken in conjunction with the accompanying drawings in which:
[0016] FIG. 1A shows a top-left perspective view of an embodiment of a hands-free measuring instrument in accordance with the present disclosure;
[0017] FIG. 1B shows a bottom-right perspective view of an embodiment of a hands-free measuring instrument in accordance with the present disclosure;
[0018] FIG. 1C shows a left-rear perspective view of an embodiment of a hands-free measuring instrument in accordance with the present disclosure;
[0019] FIG. 1D shows a right-rear perspective view of an embodiment of a hands-free measuring instrument in accordance with the present disclosure;
[0020] FIG. 2A is a rear plan view of an embodiment of a hands-free measuring instrument in accordance with the present disclosure;
[0021] FIG. 2B is a side plan view of an embodiment of a hands-free measuring instrument in accordance with the present disclosure;
[0022] FIG. 2C is a front plan view of an embodiment of a hands-free measuring instrument in accordance with the present disclosure;
[0023] FIG. 2D is a bottom plan view of an embodiment of a hands-free measuring instrument in accordance with the present disclosure;
[0024] FIG. 2E is a top plan view of an embodiment of a hands-free measuring instrument in accordance with the present disclosure;
[0025] FIG. 3A shows a top-left perspective view of another embodiment of a hands-free measuring instrument in accordance with the present disclosure;
[0026] FIG. 3B shows a bottom-right perspective view of another embodiment of a hands-free measuring instrument in accordance with the present disclosure;
[0027] FIG. 4 shows a side, cutaway view of another embodiment of a hands-free measuring instrument in accordance with the present disclosure;
[0028] FIG. 5A shows a perspective view of yet another embodiment of a hands-free measuring instrument in accordance with the present disclosure having an adjustable ruler arm in a first position;
[0029] FIG. 5B shows a perspective view of the FIG. 5A embodiment of a hands-free measuring instrument in accordance with the present disclosure having an adjustable ruler arm in a second position; and
[0030] FIG. 5C shows a partial-exploded, perspective view of the FIG. 5A embodiment of a hands-free measuring instrument in accordance with the present disclosure.
DETAILED DESCRIPTION
[0031] Particular embodiments of the present disclosure are described hereinbelow with reference to the accompanying drawings; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure, which may be embodied in various forms. Well-known and/or repetitive functions and constructions are not described in detail to avoid obscuring the present disclosure in unnecessary or redundant detail. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure in virtually any appropriately detailed structure.
[0032] As used herein, terms referencing orientation, e.g., “top”, “bottom”, “up”, “down”, “left”, “right” and the like are used for illustrative purposes with reference to the figures and corresponding axes shown therein. However, it is to be understood that an instrument in accordance with the present disclosure may be utilized in any orientation without limitation. It is also to be understood that, although the terms “first”, “second”, etc. may be used herein to describe various elements or positions, these elements or positions should not be limited by these terms. These terms are used to distinguish one element or position from another, but not to imply a required sequence of elements or positions. In this description, as well as in the drawings, like-referenced numbers represent elements which may perform the same, similar, or equivalent functions.
[0033] With reference to FIGS. 1A-1D and 2 A- 2 E, an embodiment of a hands-free measuring instrument 100 in accordance with the present disclosure is shown. The disclosed instrument 100 includes a base 116 having an upright 110 extending orthogonally therefrom. Base 116 and upright 110 may be integrally formed, and/or may be formed in whole or in part from subassemblies. In an embodiment, base 116 and upright 110 may be formed by injection molding, as described hereinbelow. As best shown in FIGS. 2D and/or 2 E, base 116 has a substantially flattened (e.g., squat) cube shape, however, it is contemplated that base 116 may have any suitable shape, including without limitation, a squat cylindrical shape, a squat prism-shape (triangular), extruded oval shape, extruded polygonal shape, and the like. A cutout 123 is defined in base 116 and is configured to retain a first bubble level vial 122 that is mounted therein in alignment with a horizontal axis (“X”) of the base. In an embodiment, first bubble level vial 122 may be retained by at least one circular recess (not explicitly shown) defined in either end of cutout 123 that is dimensioned to receive an end of first bubble level vial 122 . It should be understood that any suitable manner of retention of bubble level vial 122 may be employed, including without limitation, adhesive, plastic welding, clip, threaded fastener, and/or interference fit. Additionally or alternatively to a bubble level, other types of levels may also be employed, including without limitation, a pendulum-based levels and an accelerometer-based level (e.g., an electronic level employing an silicon accelerometer, and the like).
[0034] Base 116 may additionally or alternatively include at least one pilot hole 118 defined therein. As shown pilot hole 118 is oriented along a vertical axis (“Y”) of instrument 110 , and may be oriented along a horizontal axis (“X” or “Z”) and/or an angle thereto (e.g., at a 30°, 45°, 60°, or other desired angle thereto). During use, a carpenter may utilize the at least one pilot hole 118 to scribe a mark onto a targeted material or surface thereof. Additionally or alternatively, a carpenter may pass a fastener (nail, screw, bolt, etc.) through a pilot hole 118 to affix instrument 100 to a workpiece.
[0035] As seen in FIG. 1B , base 116 includes a first magnet 144 joined to a bottom surface 135 thereof. First magnet 144 may include a permanent magnet formed from, e.g., alnico, ceramic, ferrite, neodymium, and/or samarium cobalt material. Additionally or alternatively, first magnet 144 may include an electromagnet which may be selectively activated by an actuator, such as without limitation, a pushbutton or slide switch configured to energize or de-energize an electromagnetic coil (not explicitly shown) included within instrument 100 and/or first magnet 144 . A bottom surface of first magnet 144 may be substantially aligned with a bottom surface 135 of base 116 to facilitate sturdy placement of instrument 110 on a desired surface. As shown, first magnet 144 may be substantially disc-shaped, however it is envisioned that first magnet 144 may encompass any suitable shape.
[0036] Base 116 and/or upright 110 may be formed by any suitable manner of manufacture, including without limitation, injection-molding. In an embodiment, one or more reinforcing struts 129 may be included within base 116 and/or housing 110 . At least one semicircular strut 134 may be formed within base 116 to form a cavity (not explicitly shown) that is dimensioned to retain magnet 144 by any suitable manner of retention, including without limitation, adhesive, plastic welding, clip, threaded fastener, and/or interference fit. Magnet 144 may be formed by injection molding, and may be formed in situ by direct injection of magnetic material into a cavity formed by at least one semicircular strut 134 .
[0037] As described hereinabove, an upright 110 extends perpendicularly from base 116 . Upright 110 has a generally elongate cuboid shape having a top surface 124 , a first side surface 112 (e.g., a left side), a second side surface 114 (e.g., a right side), a front edge 130 , and a rear edge 131 . Side surfaces 112 and 114 may include a curved surface, which may have a convex contour, as best seen in, e.g., FIG. 1A . In an embodiment, a front edge 130 of upright 110 is substantially aligned with a front edge 132 of base 116 , and/or a rear edge 131 of upright 110 is substantially aligned with a rear edge 133 of base 116 . During use, the right angle arrangement of upright 100 and base 116 enables a side of upright 110 and/or base 116 to be positioned against a workpiece to establish a square reference mark, as will be readily appreciated.
[0038] A cutout 121 is defined in upright 110 that is configured to retain a second bubble level vial 122 that is mounted therein in alignment with a vertical axis (“Y”) of the instrument. In an embodiment, second bubble level vial 120 may be retained by at least one circular recess (not explicitly shown) defined in either end of cutout 121 that is dimensioned to receive an end of second bubble level vial 122 . It should be understood that any suitable manner of retention of bubble level vial 120 may be employed, as described hereinabove.
[0039] Upright 110 may include at least one notch 126 defined in a front edge 130 or a rear edge 131 thereof. The at least one notch 126 has a width that is dimensioned to accept a dry line, e.g., a width in a range of about 1/32″ to about 3/32″. In an embodiment, the at least one notch 126 is positioned at an easily-remembered distance from a bottom surface of base 116 , for example without limitation, ½″ or 1 cm. In an embodiment, upright 110 and/or base 116 may include at least one laser diode (not explicitly shown) that is adapted to selectively emit visible laser light, e.g., having a wavelength of about 650 nm, and having a beam direction that is aligned with an axis (e.g., “X”, “Y”, and/or “Z” axis) of instrument 110 . In such an embodiment, instrument 100 may be used as a laser leveling device. The at least one laser diode may be adapted to cooperate with an active target that senses laser light impinging thereon to provide audio and/or visual feedback to a user. In yet another embodiment, upright 110 and/or base 116 may include at least one electromagnetic and/or electroacoustic measuring device, e.g., a laser-based or ultrasound-based rangefinder, to enable the measurement of distances greater than the dimension of upright 110 and/or base 116 .
[0040] Upright 110 may additionally or alternatively include a series of graduations 129 disposed on a first side 112 and/or a second side 114 of upright 110 , adjacent to and substantially following a front edge 130 and/or a rear edge 131 thereof. Graduations 129 may form a ruler demarcated with any suitable unit(s) of measurement, including without limitation, Imperial units (inches and/or fractions thereof), metric units (cm, mm, etc.), and/or a combination thereof. The origin (e.g., zero point) of graduations 129 may coincide with a plane described by a top surface 124 of the upright 110 , a top surface 136 of the base 116 , and/or a bottom surface 135 of the base 116 . Advantageously, by indexing the origin of graduations 129 with, e.g., a bottom or top surface of instrument 100 , measurements of material may be easily and accurately achieved in a hands-free manner. By way of example only, during use, a carpenter may affix instrument 100 to a workpiece (using magnetic or mechanical attachment) and align the workpiece to a line using graduations 129 as a reference. When the workpiece is properly aligned to the line, the carpenter may then fasten the workpiece in place. In this manner, a user may use both hands to position and fasten the workpiece, rather than attempt to hold a conventional ruler and/or level in place while both positioning and fastening the work. Significant improvements in efficiencies and precision may thus be realized by use of an instrument 100 as disclosed herein.
[0041] A second magnet 148 may be disposed on a front edge 130 and/or a rear edge 131 of upright 110 . Second magnet 148 may be formed from any suitable magnetic material, and may be formed from thin sheet magnetic material, such as without limitation, a thermoplastic permanent magnetic extrusion formed from a polymer-bonded strontium ferrite powder. Second magnet 148 may be joined to front edge 130 and/or rear edge 131 of upright 100 by any suitable manner of attachment, e.g., pressure-sensitive adhesive. As shown, second magnet 148 has an elongate rectangular shape, however, it is contemplated that second magnet 148 may include any suitable shape, and/or may additionally or alternatively include a plurality of magnetic elements disposed on a front edge 130 and/or a rear edge 131 of upright 110 .
[0042] As described hereinabove, instrument 100 may be formed from injection molded components. In an embodiment, instrument 100 may be formed from two “clamshell” halves 100 A, 100 B, each having a base half portion and an upright half portion integrally formed therewith. Instrument halves 100 A and 100 B may be formed any material suitable for injection molding, such as without limitation, polymeric materials including acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), polyurethane (PU), polypropylene (PP), fiber-reinforced plastic (FRP), and the like. Instrument halves 100 A and 100 B may be injection-molded as described, and/or may be formed by any other suitable manner of manufacture, e.g., machining, forging, and the like, and may be formed from metallic materials such as aluminum, stainless steel, brass, etc., and/or may be formed from wood or any other material with sufficient strength and dimensional stability for use in a measuring instrument. The instrument 100 may include a grip-enhancing coating (not explicitly shown), such as a silicone-based or rubberized coating, disposed on at least a part of an outer surface thereof.
[0043] Turning now to FIGS. 3A , 3 B, and 4 , another embodiment of a measuring instrument 200 having a spike 230 in accordance with the present disclosure is described in detail. The disclosed instrument 200 includes a base 216 having an upright 210 extending orthogonally therefrom. Base 216 and upright 210 may be integrally formed, and/or may be formed in whole or in part from subassemblies as previously described herein. A cutout 223 is defined in base 216 and is configured to retain a first bubble level vial 222 that is mounted therein in alignment with a horizontal axis (“X”) of the base. In an embodiment, first bubble level vial 222 may be retained by at least one circular recess (not explicitly shown) defined in either end of cutout 223 that is dimensioned to receive an end of first bubble level vial 222 . Additionally or alternatively, any suitable manner of retention of bubble level vial 222 may be employed, as previously described hereinabove. Base 216 may additionally or alternatively include at least one pilot hole 218 disposed therein as discussed above.
[0044] Base 216 includes a first magnet 244 joined to a bottom surface 265 thereof. First magnet 244 may include a permanent magnet formed from suitable magnetic materials heretofore discussed, and first magnet 244 may include an electromagnet which may be selectively activated by an actuator (not explicitly shown). A bottom surface of first magnet 244 may be substantially aligned with a bottom surface 265 of base 216 to facilitate sturdy placement of instrument 110 on a desired surface. An opening 239 is defined within first magnet 244 that is dimensioned to accommodate the longitudinal movement of spike tip 234 therethrough. As shown, first magnet 244 may be generally disc-shaped, however it is envisioned that first magnet 244 may encompass any suitable shape.
[0045] Base 216 and/or upright 210 may be formed by any suitable manner of manufacture as described herein, including without limitation, injection-molding. One or more reinforcing struts 229 may be included within base 216 . One or more reinforcing struts 240 , 242 may be included within housing 210 . At least one semicircular strut 233 may be formed within base 216 to form a cavity (not explicitly shown) that is dimensioned to retain magnet 244 by any suitable manner of retention, including without limitation, adhesive, plastic welding, clip, threaded fastener, and/or interference fit. Magnet 244 may be formed by injection molding, as described previously herein. As shown, second magnet 248 has an elongate rectangular shape, however, it is contemplated that second magnet 248 may additionally or alternatively include any suitable shape, and/or may include a plurality of magnetic elements disposed on a front edge 230 and/or a rear edge 231 of upright 210 .
[0046] As described hereinabove, an upright member 210 extends perpendicularly from base member 216 . Upright member 210 has a generally elongate cuboid shape having a top surface 224 , a first side surface 212 (e.g., a left side), a second side surface 214 (e.g., a right side), a front edge 230 , and a rear edge 231 . Side surfaces 212 and 214 may include a curved surface, which may have a convex contour, as best seen in, e.g., FIG. 3A . In an embodiment, a front edge 230 of upright 210 is substantially aligned with a front edge 232 of base 216 , and/or a rear edge 231 of upright 210 is substantially aligned with a rear edge 233 of base 216 .
[0047] A cutout 221 is defined in upright 210 that is configured to retain a second bubble level vial 222 that is mounted therein in alignment with a vertical axis (“Y”) of the instrument. In an embodiment, second bubble level vial 220 may be retained by at least one circular recess (not explicitly shown) defined in either end of cutout 221 that is dimensioned to receive an end of second bubble level vial 222 . It should be understood that any suitable manner of retention of bubble level vial 220 may be employed, as described herein. Upright 210 may include at least one notch 226 defined in a front edge 251 or a rear edge 252 thereof. The at least one notch 226 has a width that is dimensioned to accept a dry line. In an embodiment, the at least one notch 226 is positioned at an easily-remembered distance from a bottom surface of base 216 , for example without limitation, ½″ or 1 cm. In an embodiment, upright 210 and/or base 216 may include at least one laser diode (not explicitly shown) that is adapted to selectively emit visible laser light of about the 650 nm wavelength, having a beam direction that is aligned with an axis (e.g., “X”, “Y”, and/or “Z” axis) of instrument 210 , to enable instrument 200 to be used as a laser leveling device. The at least one laser diode may be adapted to cooperate with an active target that senses laser light impinging thereon to provide audio and/or visual feedback to a user. In yet another embodiment, upright 210 and/or base 216 may include at least one electromagnetic and/or electroacoustic measuring device, e.g., a laser-based or ultrasound-based rangefinder, to enable the measurement of distances greater than the dimension of upright 210 and/or base 216 .
[0048] Upright 210 may additionally or alternatively include a series of graduations 229 disposed on a first side 212 and/or a second side 214 of upright 210 , adjacent to and substantially following a front edge 251 and/or a rear edge 252 thereof. Graduations 229 may form a ruler demarcated with any suitable unit(s) of measurement, and may have an origin that may coincide with a plane described by a top surface 224 of the upright 210 , a top surface 236 of the base 216 , and/or a bottom surface 237 of base 216 .
[0049] A second magnet 248 may be disposed on a front edge 251 and/or a rear edge 252 of upright 210 . Second magnet 248 may be formed from any suitable magnetic material, as previously described, and may be joined to front edge 251 and/or rear edge 252 of upright 200 by any suitable manner of attachment.
[0050] Instrument 200 may include a spike 230 that is adapted to enable a user to fasten instrument 200 to a workpiece, such as without limitation, a workpiece formed from wood-based materials, masonry, concrete, drywall, composite materials, and the like. Spike assembly 230 includes a shaft 232 slidably disposed along the vertical (“Y”) axis and, more particularly, shaft 232 is disposed through the general center vertical axis of upright 210 . Shaft 232 may be slidably disposed within a series of guide openings 241 , 243 , and 247 that are defined within upright 210 and which are dimensioned to permit the free movement of shaft 232 therethrough. Opening 247 may be defined within a top surface 224 of upright 210 . Openings 241 and 243 may be defined in internal support members 240 and 242 , respectively.
[0051] A biasing member 236 provides a biasing force to bias spike 230 in an upward direction, such that, at rest, spike tip 234 is retracted to a position above (e.g., not protruding downwardly beyond) bottom surface 265 of base 216 . In this manner, instrument 200 may be used without the risk of spike tip 234 being inadvertently exposed. As shown, biasing member 236 may be a coil spring, however, the use of any suitable resilient biasing member is envisioned, such as, without limitation, a leaf spring, an elastomeric polymer biasing member, and the like. As seen in FIG. 4 , biasing member 236 is disposed between internal support member 240 and a retention clip 235 provided on shaft 232 of spike 230 , however other additional or alternative arrangements of biasing member 236 and spike 230 are contemplated with departing from the spirit and scope of the present disclosure.
[0052] Spike tip 234 is disposed at a bottom end of shaft 232 . In one embodiment, spike tip 234 and shaft 232 may be integrally formed. In another embodiment, spike tip 234 and shaft 232 may be detachably coupled by any suitable manner of coupling, e.g., threaded fastener, bayonet mount, and the like, to enable a user to selectively change spike tip 234 . The ability to change spike tips may be useful, for example, when a tip becomes worn, or, to select a tip more particularly suited to a specific material. In embodiments, instrument 200 may be provided in a kit which includes several tips, e.g., a tip that is well-suited for use in wooden materials, a tip that is well-suited for use in masonry (such tip may be formed from hardened steel or carbide), a threaded tip (not explicitly shown), and so forth. A shoulder 245 may be provided at a bottom end of shaft 232 which cooperates with a positive stop 246 that is included in base 216 to prevent over-extension of spike tip 234 in a downward direction. A stop clip 248 fixed to shaft 232 cooperates with a top support 249 of upright 210 to retain spike 230 within instrument 200 . In an embodiment, instrument 200 may be formed from two “clamshell” halves having one or more alignment nubs 238 provided along a mating edge 250 thereof that are dimensioned to engage with corresponding alignment recesses defined along an opposing edge (not explicitly shown).
[0053] Various methods may be utilized to employ spike 230 to attach instrument 200 to a workpiece. Instrument 200 may be positioned on a workpiece. Force, such as a hammer blow or finger pressure, may be applied downwardly to head 231 of spike 230 to drive spike tip 234 into the workpiece, thereby attaching instrument 200 to a workpiece for use. In another variation, where a threaded tip 234 is fitted, a user may position instrument 200 on a workpiece, and apply a downward turning motion to head 231 , which in turn, screws threaded tip 234 into the workpiece thereby attaching instrument 200 to the workpiece for use. Head 231 may include at least one indentation defined in a top surface thereof to accommodate a driving tool, such as without limitation, a flat-blade screwdriver, a Philips screwdriver, a Torx, or other screw drive types as will be familiar to the skilled artisan. Head 231 may additionally or alternatively include a hex shape to accommodate, e.g., a six- or twelve-point socket and/or a square shape to accommodate, e.g., an open-end wrench or pliers. It is also envisioned that head 231 may include knurling or other grip-enhancing features to facilitate the manipulation thereof by a user. After use, spike 230 may be withdrawn from the workpiece to free instrument 200 therefrom by e.g., applying upward force to spike 230 and/or head 231 , and/or unscrewing same when a threaded tip 234 is employed.
[0054] Turning now to FIGS. 5A , 5 B, and 5 C, another embodiment of a hands-free measuring instrument 300 in accordance with the present disclosure includes an adjustable ruler arm 350 . The adjustable ruler arm 350 is rotatable around a pivoting retainer 352 that is located adjacent to a top surface 324 of an upright 310 . Pivoting retainer 352 is configured to enable the selective fixing and release of adjustable ruler arm 350 such that adjustable ruler arm 350 may be fixed at an arbitrary angle with respect to the Y axis of upright 310 . As shown, pivoting retainer 352 is a bolt having a knurled, slotted head suitable for fingertip manipulation that passes through an opening 359 defined within adjustable ruler arm 350 and is threaded into threaded opening 358 provided in upright 310 . However, it is to be understood that pivoting retainer 352 may encompass any suitable pivoting arrangement, including without limitation a thumbscrew, a stud (not explicitly shown) extending from upright 310 , or a spring-biased retainer that employs friction between upright 310 and adjustable ruler arm 350 to maintain the position of adjustable ruler arm 350 . During use, the pivoting retainer 352 is loosened or disengaged, which, in turn, enables adjustable ruler arm 350 to be positioned at a desired angle, whereupon pivoting retainer 352 is tightened or engaged to set the pivoting retainer 352 at the desired angle.
[0055] The second magnet 348 may be disposed on a front edge 330 and/or a rear edge 331 of upright 310 as described in detain hereinabove. Hands-free measuring instrument 300 includes a base 316 having a notch 360 defined therein running generally along the X axis of the base. Notch 360 is configured to provide sufficient clearance to enable an end 362 of adjustable ruler arm 350 to swing away from base 316 . Notch 360 also secures end 362 to upright 310 when adjustable ruler arm 350 is in a closed position, e.g., when adjustable ruler arm 350 is positioned as shown in FIG. 5A .
[0056] Upright 310 includes a series of angular graduations 364 disposed on a face 363 of upright 310 . Angular graduations 364 are configured to indicate an angle at which adjustable ruler arm 350 is positioned with respect to upright 310 . Angular graduations 364 may be formed by any suitable technique, including without limitation intaglio, embossing, etching, laser etching, printing, silk-screening, over- or inter-molding, and the like. In an embodiment, adjustable ruler arm 350 may include a window defined therein (not explicitly shown) that is configured to expose an indicator corresponding to the angle at which adjustable ruler arm 350 is positioned.
[0057] One or more detents 356 are disposed on face 363 of upright 310 . The one or more detents 356 are arranged concentrically about the pivot point, e.g., threaded opening 358 , of adjustable ruler arm 350 . A series of corresponding one or more notches 357 are disposed on an inner face 364 of adjustable ruler arm 350 and are configured to engage the one or more detents 356 . The detents 356 and notches 357 are configured to index the adjustable ruler arm to a predetermined position, e.g., to enable the convenient and accurate positioning of adjustable ruler arm 350 to certain angles, e.g., at 15° increments, at 1° increments, and the like. In an embodiment, the detents 356 and/or notches 357 may include a series of radial serrations extending from the pivot point, e.g., threaded opening 358 . During use, the detents 356 cooperate with the corresponding notches 357 to restrain the angle of adjustable ruler arm 350 to the precise angles imposed by the arrangement of detents 356 and notches 357 .
[0058] Turning to FIG. 6 , an embodiment of a hands-free measuring instrument 400 in accordance with the present disclosure includes one or more light source 450 disposed upon a top surface 424 of an upright member 410 and configured to project light outwardly therefrom. Light source 450 may include an incandescent bulb, a fluorescent bulb, a light pipe (e.g., fiber optic), a single-color light-emitting diode (LED), and/or a multi-color LED. Instrument 400 further includes one or more light source 452 disposed on a side face 414 of upright 410 . Light sources 452 are mounted in a recessed region 453 defined in side face 414 . Recessed region 453 includes a reflective surface 456 that is configured to reflect and/or diffuse the radiated light from light sources 452 . A transparent lens 454 is disposed over the open face of recessed region 453 .
[0059] A multi-mode light actuator 458 is provided on an external surface of instrument 400 that is configured to selectively activate and deactivate light sources 450 , 452 . Multi-mode light actuator 458 may include a pushbutton switch, a slide switch, a snap dome switch, or any other suitable switch. Repeated actuation of multi-mode light actuator 458 cause light sources 450 , 452 to cycle through a series of different illumination patterns. In one embodiment, a first actuation of light actuator 458 causes one or more light source 450 to illuminate. A second actuation of light actuator 458 deactivates the one or more light source 450 and causes one or more light source 452 to illuminate. A third actuation of light actuator 458 causes both light sources 450 and 452 to illuminate. A fourth actuation of light actuator 458 deactivates both light sources 450 , 452 . In other embodiments, actuation of multi-mode light actuator 458 may cause other combinations of light sources 450 , 452 to be selectively illuminated. For example, and without limitation, an actuation of multi-mode light actuator 458 causes light sources 450 and/or 452 to illuminate with a flashing pattern with a duty cycle of, e.g., 2 Hz. A subsequent actuation of multi-mode light actuator 458 causes light sources 450 and/or 452 to illuminate with a various colors, e.g., cycling through white, red, green, or other colors. In yet another embodiment, a rapid double actuation of multi-mode light actuator 458 , e.g., two actuations within 0.5 seconds will cause light sources 450 and/or 452 to extinguish.
[0060] The described embodiments of the present disclosure are intended to be illustrative rather than restrictive, and are not intended to represent every embodiment of the present disclosure. Further variations of the above-disclosed embodiments and other features and functions, or alternatives thereof, may be made or desirably combined into many other different systems or applications without departing from the spirit or scope of the disclosure as set forth in the following claims both literally and in equivalents recognized in law. | A hands-free measuring instrument is disclosed. The disclosed instrument includes an upright member extending perpendicularly from a base member. At least one magnet is affixed to the instrument to facilitate the mounting thereof on a ferrous workpiece. The disclosed instrument includes at least one level disposed thereupon. Graduations may be provided on the instrument to facilitate measurement of linear distances. Embodiments are disclosed wherein an adjustable ruler arm is provided to facilitate the measurement and inscribing of arbitrary angles relative to the upright member. | 6 |
FIELD OF THE INVENTION
The present invention concerns a method for adjusting the throttle and/or injection quantity of a motor vehicle combustion engine as an input of a vehicle driver.
RELATED TECHNOLOGY
Adaptive engine systems which adapt to the driving style of a driver are disclosed, for example, in German Patent Application No. 44 01 416 A1, according to which, the vehicle driver's individual driving style is evaluated. According to the method described in German Patent Application No. 44 01 416 A1, the evaluation basically includes evaluating the accelerations measured in the lengthwise and transverse directions of the vehicle. From the heretofore methods described in German Patent Application No. 44 01 416 A1, evaluating the driving style of the vehicle driver by the type of actuation of, among other things, the accelerator pedal is disclosed. Consideration of individual driving style then occurs in that an intervention can be made into engine/transmission management depending on the evaluation.
SUMMARY OF THE INVENTION
According to the present invention, the characteristic curve of throttle angle position or injection quantity over the accelerator pedal angle position exhibits a progressive characteristic during driving behavior recognized as conservative and a degressive characteristic during driving behavior recognized as sporty.
A progressive characteristic particularly indicates that for small accelerator pedal angles there is a flat rise and there is a greater rise only for greater angles. Accordingly, the degressive characteristic in driving behavior recognized as sporty indicates in particular that at small accelerator pedal angles, at first there is a steep rise which flattens out with greater accelerator pedal angles.
Advantageously, because of this, during conservative driving behavior where the command is derived from the accelerator pedal position, the angle range of throttle position or the injected quantity normally set by the vehicle driver is assigned a greater angle range of accelerator position. Because of this, metering that feels more sensitive is possible with conservative driving behavior. In addition, advantageously during driving behavior that is recognized as sporty, larger throttle angle range and/or injection quantity is assigned to similarly small accelerator pedal angle settings. Because of this, a similarly more agile metering behavior during sporty driving is possible when there is driving behavior that is recognized as sporty.
In conventional systems, with a fixed curve, dimensioning in the sense of similarly sensitive metering can only be realized with restrictions. In fact, if the system is adjusted to a vehicle driver with conservative driving behavior, the fine sensitivity of the metering is thus impaired for a vehicle driver with more sporty driving behavior. Similarly, the fine sensitivity of metering is impaired for a vehicle driver with conservative driving behavior if the system is designed for a vehicle driver with sporty driving behavior.
In a further adaptation of the present method, at least one intermediate value exists for driving behavior recognized as being situated between driving behavior recognized as conservative and driving behavior recognized as sporty. For this at least one intermediate value, there also exists a curve which lies between the curve with the progressive characteristic for driving behavior recognized as conservative and the curve with the degressive characteristic for driving behavior recognized as sporty.
In this way, at least one more level is possible for finer adjustment to the driving behavior of the vehicle driver.
Furthermore, driving behaviors between driving behavior recognized as conservative (in other words steady) and driving behavior recognized as sporty may be graduated continuously. The assignment of curves is also continuous.
Because of this, a subdivision of the individual driving behaviors of individual vehicle drivers that is still more differentiated and the appropriate curve assignment becomes possible.
Yet further, the curves may be varied depending on vehicle speed. This advantageously considers driving resistance. With conservative driving behavior, for example, curve a in FIG. 3 may be only permitted at speeds less than 100 km/h since at high speeds driving resistance adequately retards the vehicle. During driving behavior recognized as sporty, for example, at speeds greater than 100 km/h, only dynamic curve b of FIG. 3 may be permitted. The increase in dynamic response is continuously reduced as the speed drops in order to make it possible to control the vehicle even here.
The accelerator position may used as a command from the vehicle driver, while the signal for this accelerator position is subject to low-pass filtering that is clearly perceptible in the driving performance, at least under certain conditions.
Because of this, abrupt changes in driving performance can be advantageously prevented. This increases driving comfort.
One of the specific certain conditions includes that the recognized driving behavior lies below a specific threshold value of a driving behavior recognized as sporty.
Because of this, low-pass filtering occurs only during a driving style that is more conservative. Thus higher driving comfort can be achieved corresponding to the driving style of the vehicle driver with a conservative driving style, and with a more sporty driving style there is a more dynamic response of the vehicle upon accelerator actuation by the vehicle driver.
Another of the specific conditions may be that the accelerator pedal is not returned or released at a speed lying above a specific threshold. This advantageously permits a request for a relatively substantial vehicle deceleration to be implemented without time delay.
Low-pass filtering parameters may be set depending on the recognized driving behavior. Thus the relationship between driving comfort and dynamic response of the vehicle to accelerator pedal actuation by the vehicle driver can be adjusted more precisely depending on the degree of conservative driving behavior and/or a tendency for sportier driving behavior.
A variable may used as an input by the vehicle driver that is formed by considering the accelerator pedal position and, at least under certain circumstances, the time derivative of the accelerator pedal position. The accelerator pedal actuation dynamics upon command from the vehicle driver thus can advantageously be considered.
The specific certain circumstances can include the fact that the recognized driving behavior lies above a specific threshold for sporty driving behavior. Because of this, consideration of the dynamics can advantageously be prevented in the case of conservative driving behavior.
The time derivative of accelerator pedal position may be increasingly considered for the variable formation, as the driving behavior is increasingly recognized as sporty. Due to this, dynamics will be increasingly considered as driving behavior increasingly becomes sportier.
During a spontaneous dynamic response request by the vehicle driver that is recognized independently of previously recognized driving behavior, the throttle setting and/or injection quantity may depend on the spontaneous dynamic request, independently of the previously used curve based on recognized driving behavior.
This has an especially advantageous effect during conservative driving behavior. Because of the curve characteristic, in fact, the vehicle driver would have to actuate the accelerator pedal far enough until he achieves an appropriate setting of the throttle and/or injection quantity based on the curve characteristic. If vehicle acceleration is desired, this can result in a delay. This is advantageously prevented by recognition of a spontaneous dynamic response request. Recognition of the spontaneous dynamic response request can occur, e.g., by a method that has been described in commonly-assigned German Patent Application No. 19729251.8, which is hereby incorporated by reference herein, and in the corresponding U.S. patent application, filed on Jul. 9, 1998, entitled "Method for Recognizing a Spontaneous Demand by a Driver of a Motor Vehicle for a Dynamic Response," which is also hereby incorporated by reference herein.
With a recognized spontaneous dynamic response request, the medium driving behavior curve (for example, curve c in FIG. 3) may be used as the characteristic curve. Because of this, a similarly greater vehicle acceleration can be set more quickly.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the present invention is shown in more detail in the drawings. In particular:
FIG. 1 shows one embodiment in the form of a block diagram for considering dynamic variation of the assignment of accelerator pedal position to throttle position and/or to injection quantity which may be carried out for example, using a microprocessor having inputs from a vehicle sensor system and the accelerator pedal,
FIG. 2 shows one embodiment in the form of a block diagram for considering static variation of the assignment of accelerator pedal position to throttle position and/or injection quantity, and
FIG. 3 shows a set of curves for carrying out static variation of assignment of accelerator pedal position to throttle position and/or injection quantity.
DETAILED DESCRIPTION
FIG. 1 shows a block diagram that considers dynamic variation of the assignment of accelerator pedal position to throttle position and/or to injection quantity. In Block 101, first the individual vehicle driver's driving style is determined. Therefore, in this block there is also a recognition of driving behavior. This can be carried out, e.g., according to the method described in German Patent Application No. 44 01 416 A1, which advantageously uses the longitudinal acceleration parameter biz of the method described there and which is hereby incorporated by reference herein. However, it is also basically possible to use other methods for rating driving behavior between conservative and sporty.
In addition, it can be seen that in Block 102 there is an evaluation that recognizes a spontaneous dynamic response request from the vehicle driver. This can be carried out, for example, according to the method described in incorporated-by-reference German Patent Application No. 19729251.8 and its corresponding U.S. Patent Application. In these documents, a variable kfb is determined for recognizing a spontaneous dynamic response request and therefore Block 102 is an abbreviated representation of the method described in these documents. If a spontaneous dynamic response request has been recognized, assignment of the vehicle driver's command is set by the accelerator pedal position independently of previously recognized driving behavior.
In Block 103, the change dpw of the accelerator position over time is formed from accelerator pedal position pw.
In Block 104, the driving behavior recognized is compared to a specified threshold value. In the embodiment shown, variable bkz is used for recognizing driving behavior so that in Block 104 a comparison takes place between this variable bkz and a specified threshold value of this variable bkz.
In this comparison, if variable bkz is less than the threshold value, the process continues with Block 105. The signal representing accelerator pedal position is damped. Advantageously, this damping d--as shown in Block 105--can be influenced by other variables. For example, damping d can be applied depending on the driving behavior that is recognized as more conservative or more sporty. Also it is possible to determine damping d depending on variable kfb, with the help of which a spontaneous dynamic response request is recognized. Also damping d can be determined as a function of accelerator pedal position pw and/or the time derivative of accelerator position dpw.
The process then continues in Block 106, in which the accelerator pedal signal is damped. For further adjustment of the throttle and/or injection quantity, pw -- dyn is then used.
An object of damping in Blocks 105 and 106 is to set a greater damping, the more conservative the vehicle driver's driving behavior is. If a quick pedal release or pedal zero position occurs, damping is switched off immediately in order to initiate the desired vehicle deceleration without delay.
If it has been determined in Block 104 that variable bkz is greater than the threshold of bkz, variable pw -- dyn is formed in that the time derivative of accelerator pedal dpw, multiplied by variable c, is added to accelerator pedal position pw.
Variable c can, for example, be varied in Block 107 depending on the driving behavior recognized. With increasingly sporty driving behavior, this variable becomes greater resulting in faster vehicle response to a change in accelerator pedal position in the direction of acceleration.
In Block 108 then, variable pw-dyn is determined by addition of accelerator pedal position and the change in accelerator pedal position over time multiplied by variable c:
pw.sub.-- dyn=pw+c* dpw.
Naturally, adapting the parameters to the recognized driving behavior without checking in Block 104 in such a way that damping continuously approaches 0 with increasingly sporty driving behavior and variable c approaches 0 with increasingly conservative driving behavior lies within the scope of the present invention.
FIG. 2 shows an embodiment of a block diagram for considering static variation in assignment of the accelerator pedal position to throttle position and/or to injection quantity.
Block 101 corresponds to Block 101 in FIG. 1. Here as well, driving behavior is evaluated and recognized as more conservative or more sporty. In the embodiment in FIG. 2, acceleration identifier biz is also used for further evaluation.
In Block 202, the spontaneous dynamic response request is recognized according to the method described in incorporated-by-reference German Patent Application No. 19729251.8 and its also incorporated-by-reference corresponding U.S. Patent Application. Variable kfbbit characterizes whether a spontaneous dynamic response request is present or not.
In addition, signal v representing vehicle speed is supplied to Block 203, as well as the signal of accelerator pedal position representing the vehicle driver's command that was determined as variable pw -- dyn as shown in FIG. 1.
If a spontaneous dynamic response request is present (kfbbit set), for example, at least center curve c is used in order to ensure appropriately dynamic vehicle response without additional consideration of previously recognized driving behavior.
If bit kfbbit has not been set, a curve can be evaluated using the driving behavior recognized. In FIG. 3, for example, a few curves are shown that will be described in more detail in the following.
Furthermore, the curve corresponding to vehicle speed can be varied to consider driving resistance. For example, with conservative driving behavior, curve a in FIG. 3 may be permitted only at speeds less than 100 km/h, since at high speeds driving resistance adequately retards the vehicle. During driving behavior recognized as sporty, for example, at speeds greater than 100 km/h, only dynamic curve b of FIG. 3 may be permitted. The increase in dynamic response is continuously reduced as the speed drops in order to make it possible to control the vehicle even here.
In step 204, adjustment of throttle and/or injection quantity is carried out using variable pw -- dyn that has been determined.
FIG. 3 shows a set of curves for carrying out static variation of assignment of accelerator pedal position to throttle position and/or to injection quantity.
The selection of curves is carried out according to the degree of curve variation var determined in step 203 for driving behavior recognized as conservative or sporty. The direction of the arrow for variable var shows the selection of the curve with driving behavior recognized as increasingly sporty.
Curve a corresponds to conservative driving behavior, curve b to sporty driving behavior and curve c to medium driving behavior.
In FIG. 3, variable pw -- dyn stat is plotted against variable pw -- dyn. For example, the throttle position and/or the injection quantity can be directly proportional to variable pw -- dyn stat (curve c).
Thus it also proves to be advantageous that particularly good consideration of the driving behavior recognized is possible if both assignment of throttle position and/or injection quantity to accelerator pedal position is carried out depending on the driving behavior recognized, as well as an assignment of throttle position and/or of injection quantity to the change in accelerator pedal position over time depending on recognized driving behavior. | A method for adjusting the throttle and/or injection quantity of a motor vehicle combustion engine at the command of a vehicle driver, an adaption being made to the vehicle driver's driving style, the curve of angle throttle position and/or injection quantity over accelerator pedal position angle exhibiting a progressive characteristic when there is driving behavior recognized as conservative and a degressive characteristic when there is driving behavior recognized as sporty. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates a system and method for operating a fuel cell system and, more particularly, to a system and method for controlling fuel cell system shut-down operations.
BACKGROUND
[0002] Fuel cells are electrochemical devices that convert chemical energy in fuels into electrical energy directly. In a typical operating cell, fuel is fed continuously to the anode (the negative electrode) and an oxidant is fed continuously to the cathode (positive electrode). Electrochemical reactions take place at the electrodes (i.e., the anode and cathode) to produce an ionic current through an electrolyte separating the electrodes, while driving a complementary electric current through a load to perform work (e.g., drive an electric motor or power a light). Though fuel cells could, in principle, utilize any number of fuels and oxidants, most fuel cells under development today use gaseous hydrogen as the anode reactant (aka, fuel) and gaseous oxygen, in the form of air, as the cathode reactant (aka, oxidant).
[0003] To obtain the necessary voltage and current needed for an application, individual fuel cells may be electrically coupled to form a “stack,” where the stack acts as a single element that delivers power to a load. The phrase “balance of plant” refers to those components that provide feedstream supply and conditioning, thermal management, electric power conditioning and other ancillary and interface functions. Together, fuel cell stacks and the balance of plant make up a fuel cell system.
[0004] Referring to FIG. 1A , fuel cell 100 (shown in a top-down view) is configured to include anode inlet 105 , anode outlet 110 , cathode inlet 115 , cathode outlet 120 , coolant inlet 125 and coolant outlet 130 . Referring to FIG. 1B , as noted above fuel cells (e.g., fuel cell 100 ) may be stacked to create fuel cell stack 135 , wherein each cell's anode, cathode and coolant passages are aligned.
[0005] One operational issue unique to fuel cell systems concerns system start-up and shut-down operations. Unlike internal combustion power plants, fuel cell electrodes may be damaged if exposed to improper gases and/or gas mixtures. For example, an anode's exposure to air can be very damaging to the cell if not done properly. Similarly, shut-down operations that generate mixtures of gasses (e.g., hydrogen-air solutions) may detrimentally affect the fuel cell system during subsequent start-up operations.
SUMMARY
[0006] In general, the invention provides methods to shutdown a fuel cell system. A method in accordance with one embodiment includes halting the flow of fuel and, thereafter, initiating the flow of an inert gas (e.g., nitrogen) to the anodes of a fuel cell stack while maintaining the flow of oxidizer to the cathodes. A load is then cyclically engaged and disengaged across the fuel cell stack so as to deplete the fuel available to the system's fuel cells. Voltage and/or current thresholds may be used to determine when to engage and disengage the load and when to terminate the shutdown operation. Once the fuel cells are substantially depleted of fuel, an oxidizer fluid may be flowed across both the anode and cathodes with the load engaged until a second voltage and/or current threshold is met. The oxidizer fluid flow may then be halted and the load disengaged. In another embodiment, a variable load is engaged and adjusted so as to deplete the fuel available to the system's fuel cells. As noted above, voltage and/or current thresholds may be used to determine when to adjust the load and when to terminate the shutdown process. In still another implementation, a load may be periodically engaged and disengaged during some portion of the shutdown process and engaged but adjusted during other portions of the shutdown process.
[0007] Methods in accordance with the invention may be performed by a programmable control device executing instructions organized into one or more program modules. Programmable control devices comprise dedicated hardware control devices as well as general purpose processing systems. Instructions for implementing any method in accordance with the invention may be tangibly embodied in any suitable storage device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Figure A shows the layout of a single fuel cell ( 1 A) and fuel cell stack ( 1 B) in accordance with conventional prior art fuel cell technology.
[0009] FIG. 2 shows a fuel cell system in accordance with one embodiment of the invention.
[0010] FIG. 3 shows a shutdown process in accordance with one embodiment of the invention.
[0011] FIG. 4 shows a fuel cell system in accordance with another embodiment of the invention.
[0012] FIG. 5 shows a shutdown process in accordance with another embodiment of the invention.
DETAILED DESCRIPTION
[0013] The following description is presented to enable any person skilled in the art to make and use the invention as claimed and is provided in the context of the particular examples discussed below, variations of which will be readily apparent to those skilled in the art. More specifically, illustrative embodiments of the invention are described in terms of fuel cells that use gaseous hydrogen (H 2 ) as a fuel, oxygen (O 2 ) as an oxidant in the form of air (a mixture of O 2 and nitrogen, N 2 ) and proton exchange or polymer electrolyte membrane (“PEM”) electrode assemblies. The claims appended hereto, however, are not intended to be limited by the disclosed embodiments, but are to be accorded their widest scope consistent with the principles and features disclosed herein.
[0014] Referring to FIG. 2 , in one embodiment of the invention fuel cell system 200 includes fuel cell stack 205 , balance of plant 210 , load 215 and switch 220 . Fuel cell stack 205 includes a plurality of fuel cells, aligned as illustrated in FIG. 1B , with unsealed anodes and cathodes. As used herein, the term “unsealed” means that the designated element (e.g., anode) cannot hold a vacuum and is, when not operating, at substantially ambient pressure. As discussed in more detail below, in one embodiment, switch 220 is periodically cycled (i.e., closed and opened) to permit substantially all of the fuel present at, and in, the stack's anodes to be consumed in a safe, convenient and relatively rapid manner.
[0015] Referring to FIG. 3 , in one embodiment shutdown operation 300 begins by terminating H 2 flow and, thereafter, initiating the flow of N 2 or some other inert gas across the anode (block 305 ). In one embodiment, a single anode's volume of nitrogen is used in this manner. In another embodiment, nitrogen flow is maintained for the process' entire duration. In yet another embodiment, no nitrogen purge is used. The general purpose of using nitrogen in this way is to remove or purge much of the fuel present at the anode although, it will be recognized, relatively large amounts of H 2 may remain absorbed in the electrode's catalyst. In general, if nitrogen is available, the minimum amount of nitrogen used in this manner would be one anode's volume, while the maximum nitrogen flow would be continued for the entire duration of the hydrogen consumption. Following initiation of the N 2 purge and in light of the continued O 2 /air flow across the cathode, switch 220 is closed to engage load 215 (block 310 ). In practice, load 215 may be engaged before, simultaneously with or following the initiation of N 2 purge operations.
[0016] It will be recognized that balance of plant 210 includes fuel cell stack sensors such as, for example, voltage and/or current sensors for monitoring the activity of each, most or some fuel cells in fuel cell stack 205 . These sensors may be used in accordance with the invention to determine when each discharge cycle (block 315 ) is complete and when all discharge cycles are complete (block 325 ).
[0017] Generally speaking, with load 215 engaged the voltage across each fuel cell will decrease as fuel at and within the cell's anode is consumed. For those implementations which monitor cell voltages, while the measured voltages remain above a specified first threshold (the “No” prong of block 315 ), load 215 remains engaged. When the measured voltages drop to this first specified threshold (the “Yes” prong of block 315 ), load 215 is disengaged via switch 220 (block 320 ). If all discharge cycles have not been completed (the “No” prong of block 325 ), a pause is provided to allow fuel cell voltages to equalize (block 330 ) before load 215 is reengaged (block 310 ). When the monitored fuel cell voltages indicate all discharge cycles have been completed (the “Yes” prong of block 325 ), N 2 flow across the anode is halted (if it is still active), load 215 is engaged and O 2 /air flow is initiated across the anode (while maintaining O 2 /air flow across the cathode) until all monitored fuel cell voltage's are below another specified threshold. At this point, fuel cell system 200 has been prepared for shutdown and all O 2 /air flow and further monitoring may be terminated (block 335 ).
[0018] In one embodiment, a cycle is considered completed when any monitored (typically minimum) fuel cell's voltage drops to a specified value. Illustrative specified values include 0, 5, 10, 20, 50 and 75 millivolts (“mv”). In like manner, all discharge cycles may be considered complete when any monitored (typically minimum) fuel cell's voltage reaches a specified lower-limit value (e.g., 0, 5, 30, 50 or 75 mv) and the maximum monitored fuel cell's voltage is at or below a specified upper-limit voltage (e.g., 100, 150 or 200 mv). In another embodiment, the total stack voltage is monitored to determine when all hydrogen has been consumed (e.g., when the total stack voltage falls to a specified level or voltage—although it will be understood that it is presently important to ensure that no monitored cell's voltage drops below typically, zero mv). In accordance with the acts of block 335 , air flow is then initiated to the anode (recall, air flow is already provided to the cathode) with load 215 engaged until all monitored fuel cell voltages' drop to yet another threshold (e.g., 10, 25, 50 or 75 mv). While the values provided here are illustrative, one of ordinary skill in the art will recognize that the precise values applicable to any given implementation will be dependent on a number of design factors such as, for example, the number of fuel cells in fuel cell stack 205 , the type of electrode used, the type of fuel and oxidant employed, the electrical resistance provided by load 215 and the age, age distribution and homogeneity of the fuel cells in fuel cell stack 205 .
[0019] By way of example only, in a fuel cell system employing H 2 fuel, O 2 /air oxidant, a 220 cell fuel cell stack, PEM electrode assemblies and a 10 ohm (“Q”) load, a cycle is considered complete whenever any single monitored fuel cell's voltage drops to 0 mv. All discharge cycles are considered complete when any single monitored fuel cell's voltage drops to 25 mv and the maximum voltage measured at any monitored fuel cell is 200 mv. Following detection of this “all discharge cycles complete” condition, the load is engaged and air flow is initiated to both the anode and cathode until all monitored fuel cells register a voltage of 50 mv or less. Beginning with a substantially fully-charged fuel cell stack, an inter-cycle pause of between 1 to 2 seconds is typical. Start to finish, the described shutdown operation on the system identified here takes approximately 300 seconds, with load 215 engaged for about 60 seconds of this time over approximately 100 cycles.
[0020] Referring to FIGS. 4 and 5 , in another embodiment fuel cell system 400 utilizing variable load 405 may be shutdown in accordance with procedure 500 . In this approach, variable load 405 is continuously engaged and periodically adjusted so as to reduce the monitored fuel cell voltages' to a specified shutdown value. Referring again to FIG. 5 , in this approach fuel flow is terminated and a purge using N 2 or some other inert gas is initiated across the anode (block 505 ). Next, and while O 2 /air flow across the cathode is maintained, switch 220 is closed to engage variable load 405 (block 510 ). As before, load 405 may be engaged before, simultaneously with or following the initiation of N 2 purge operations. Initially, variable load 405 is set to a relatively high value so that little current flow is extracted from fuel cell stack 205 . In general, load 405 would initially be set to a relatively low value and slowly increased with time based on keeping the minimum monitored cell's voltage above a specified lower threshold (e.g., 0, 5, 30, 50 or 75 mv). While the fuel cells have not been depleted of residual fuel (the “No” prong of block 515 ), load 405 may be periodically adjusted (block 520 ). When the measured fuel cell voltages drop to a first specified threshold (the “Yes” prong of block 515 ), the N 2 purge is terminated and air flow across the anode is initiated. When the monitored fuel cell voltages are at a second threshold, load 405 is disengaged via switch 220 and air flow to both the anode and cathode is terminated (block 525 )—completing shutdown operation 500 .
[0021] In still another embodiment, applicable to both of the above described operations, anode fluid (e.g., N 2 or another inert gas) may be recirculated so as to pass the same fluid over the anode multiple times. Doing this tends to keep fuel cell voltages more constant and as a result, the load (e.g., 215 and 405 ) may be left engaged for longer periods of time—all other factors remaining the same. In yet another embodiment, maximum value cell voltages may be ignored. For example, as noted above a minimum fuel cell threshold may be used to determine when a cycle is complete and an average voltage level may be used to determine when the shutdown operation is complete (e.g., block 325 and 515 ). Implementations of this sort may simplify the process by performing a specified number of cycles. In yet another implementation, loads may be engaged and disengaged for specified amounts of time and for a specified number of cycles.
[0022] In some embodiments, a fuel cell operational parameter other than voltage may be used to control the load. In principal, any fuel cell operational parameter indicative of the fuel cell's capacity to produce power may be used. For example, shutdown procedure 300 may use the rate of voltage decline during load engagement or the amount of current drawn from fuel cell stack 205 to determine when each or all discharge cycles are complete. It will be further recognized, shutdown procedure 500 may use similar operational parameter tests during the acts of block 515 .
[0023] It will be recognized that using materials currently available, it is desirable to maintain monitored fuel cell voltages above zero to minimize carbon corrosion of the fuel cells' electrodes. As different materials become available, this consideration may become less significant. As a result, fuel cell voltages may be allowed to drop closer to zero or even go “negative” before determining that each cycle (e.g., block 315 ) or all cycles (e.g., 325 and 515 ) are complete.
[0024] Various changes in the materials, components, circuit elements, as well as in the details of the illustrated operational methods are possible without departing from the scope of the following claims. For instance, the illustrative systems of FIGS. 2 and 4 are not limited to hydrogen fueled, air oxidized fuel cell systems. In addition, switch 220 may be of any type practical—e.g., electromechanical or electronic. Further, the embodiments of FIGS. 3 and 5 are illustrative only. For example, aspects of both shutdown operations 300 and 500 may be combined; a load may be periodically engaged and disengaged during one epoch and continuously engaged during a second epoch of the shutdown operation—either approach may be used first. In addition, acts in accordance with FIGS. 3 and 5 may be performed by a programmable control device executing instructions organized into one or more program modules. Further, the systems of FIGS. 2 and 4 and the processes of FIGS. 3 and 5 are applicable to sealed anode and/or cathode systems. A programmable control device may be a single computer processor, a special purpose processor (e.g., a digital signal processor, “DSP”), a plurality of processors coupled by a communications link or a custom designed state machine. Custom designed state machines may be embodied in a hardware device such as an integrated circuit including, but not limited to, application specific integrated circuits (“ASICs”) or field programmable gate array (“FPGAs”). Storage devices suitable for tangibly embodying program instructions include, but are not limited to: magnetic disks (fixed, floppy, and removable) and tape; optical media such as CD-ROMs and digital video disks (“DVDs”); and semiconductor memory devices such as Electrically Programmable Read-Only Memory (“EPROM”), Electrically Erasable Programmable Read-Only Memory (“EEPROM”), Programmable Gate Arrays and flash devices. | Processes to shut down a fuel cell system are described. In one implementation ( 300 ), a load ( 215 ) is cyclically engaged and disengaged across a fuel cell stack ( 205 ) so as to deplete the fuel available to the system's fuel cells ( 205 ). Voltage and/or current thresholds may be used to determine when to engage and disengage the load ( 215 ) and when to terminate the shutdown operation. In another implementation ( 500 ), a variable load ( 405 ) is engaged and adjusted so as to deplete the fuel available to the system's fuel cells ( 205 ). As before, voltage and/or current thresholds may be used to determine when to adjust the load ( 405 ) and when to terminate the shutdown process. In still another implementation, a load ( 215 or 405 ) may be periodically engaged and disengaged during some portion of the shutdown process and engaged but adjusted during other portions of the shutdown process. | 7 |
BACKGROUND OF THE INVENTION
This invention relates generally to paper pulp processing machinery and more particularly to rejects drainers such as those for separating knots or other coarse particles from an acceptable pulp slurry.
Processing of wood pulp for papermaking requires removal of knots and other coarse undigested particles from the pulp slurry. This is commonly accomplished in a knot drainer, in which the pulp slurry is passed through a screen upon which the knots are retained. The knots are scraped or otherwise removed from the screen and discharged from the drainer.
Knot drainers consist usually of either high speed horizontal vibratory generally flat surfaced screens or screw type drainers. The screw type drainers may be either stationary cylindrical screen type or rotary screen type machines, which may have either horizontal or vertical axes of rotation, although the vertical axis is more commonly used today. One such rotary screen type drainer is described in a pending U.S. patent application having Ser. No. 610,696, filed Nov. 8, 1990, now U.S. Pat. No. 5,143,220 and commonly assigned herewith. In the latter case the screen is attached to the outer edge of the knot transport screw flights and rotates with them. The knots travel up the screw flights in response to inertial forces which overcome gravity, hydrodynamic forces, and the friction between the knots and the screw flight. Acceptable fibers pass through the screen perforations so that the knots are ultimately discharged from the drainer in a relatively clean condition. The rotary screen screw type knot drainer provides the advantage of eliminating relative motion between the screw flight and the screen. By comparison with non-rotating screen drainers, the rotating screen drainer has less wear and tear, because it eliminates collisions which would be caused by screen and screw irregularities if the screen were not rotating, and it also eliminates the knot crushing or grinding that would result from relative motion between the screw flights and the screen. Since knots are not crushed or ground, the acceptable fiber slurry, passing through the screen perforations, is not contaminated with knot dirt and ground-off wood particles detrimental to pulp and paper making quality.
Vibratory screen type knot drainers are known to require significant maintenance and repair due to fatigue and wear damage to the vibrating parts and structure. Stationary screen screw type knot drainers experience wear due to contact between irregularities of the screw and the screen as well as the crushing and grinding action already described. In addition, they also yield an increased debris content in the pulp slurry which can ultimately degrade paper quality.
Rotary screen screw type knot drainers experience lower incidence of fatigue damage, lower wear damage as a result of virtual elimination of crushing and grinding action, and, thus, last longer and produce cleaner pulp. One such vertical axis knot drainer has a tangential feed slurry inlet chamber at the bottom, a rotatable screw flight extending generally from the inlet chamber upward to the knot discharge chamber, a rotatable screen basket attached to the lower portion of the rotatable screw flight to define a screening chamber, and a knot washing and liquid separating stationary housing extension communicating between the screening chamber and the knot discharge chamber and encasing the upper extension of the rotatable screw flight.
Simply stated, in this knot drainer, the knot containing pulp slurry is introduced through the tangential inlet into the inlet chamber and flows spirally upward into the screening chamber. The screw conveyor flight transports the knots contained in the pulp slurry through the screening chamber in which the acceptable pulp fibers pass through the perforations in the rotating screen. Above the screening chamber, the screw conveyor flight continues to transport the knots through the fiber wash-off zone and liquid separation and drain-off zone of the stationary housing extension to the knot discharge chamber. The tangential feed is desirable because it promotes centrifugal separation of stones and other heavy "junk" materials that may be included in the feed pulp slurry so that they may be accumulated for ultimate discharge from the knot drainer through a special outlet.
The vertical axis rotary cylindrical screen type knot drainer just described is, however, subject to knot transport interruptions which necessitate shutdowns to clean out the system. It has been determined that, independent of the operating speed of the knot drainer, the pulp consistency, and geometric relationships within the knot drainer, unacceptable knot transport interruptions, with subsequent knot accumulation, occur both in the screening chamber and in the housing extension. These interruptions result in knot accumulation on the screw flights which creates serious dynamic imbalance, can seriously impact the production capacity through the knot drainer unit, and may, thus, require costly maintenance, production downtime and expensive duplication of equipment to maintain production flow during shutdown necessitated by knot transport interruptions.
The foregoing illustrates limitations known to exist in present devices and methods. Thus, it is apparent that it would be advantageous to provide an alternative directed to overcoming one or more of the limitations set forth above. Accordingly, a suitable alternative is provided including features more fully disclosed hereinafter.
SUMMARY OF THE INVENTION
In one aspect of the present invention, this is accomplished by providing, in a device for separating coarse particles from a liquid borne slurry, and having an inlet chamber, a feed chamber, a screening chamber, a helical conveyor flight, through a wash and liquid separation chamber, and a liquid free coarse particle discharge chamber, the improvement, in combination with that device, comprising means for altering a dynamic force balance which acts upon the coarse particles during their transport through said device from the inlet chamber, through the feed chamber, through the screening chamber, and through the wash and liquid separation chamber to the discharge chamber.
The foregoing and other aspects will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially sectional fragmentary schematic view showing the overall configuration of a vertical axis cylindrical screen screw type rotary knot drainer incorporating the present invention;
FIG. 2 is a fragmentary schematic plan view showing the vortex reducing baffle feature of the present invention;
FIGS. 3A and 3B are fragmentary elevation views from line 3--3 of FIG. 2 showing possible alternative vortex reducing baffle configurations;
FIG. 4 is a fragmentary schematic elevation view of a portion of the screen basket illustrating part of the transport enhancement feature in that region of the knot drainer;
FIG. 5 is a view from line 5--5 of FIG. 4 showing the preferred embodiment of that transport enhancement feature;
FIG. 6 is a view from line 6--6 of FIG. 4 showing an alternative embodiment of that transport enhancement feature;
FIG. 7 is a fragmentary schematic view of the stationary housing extension above the screening chamber illustrating the transport enhancement feature in that region of the knot drainer; and
FIGS. 8A, 8B, and 8C are views from lines 8A--8A, 8B--8B, and 8C--8C, respectively, of FIG. 7 to illustrate three possible groove type cross-sectional configurations.
DETAILED DESCRIPTION
FIG. 1 presents an overall representation of a rotary screen screw type knot drainer 100. A knot bearing slurry is fed through the tangentially oriented inlet into inlet chamber 10 which is bounded on the top by downward spiralling plate 13 which defines the bottom of accepts chamber 35, radially outward from the screening chamber 20. The inner wall 11 of inlet chamber 10 is elevated slightly above the bottom 102 of the knot drainer housing 101 to provide a communicating path from the inlet chamber 10 through feed chamber 103, defined by surface 104 of wall 11 and bearing housing 12, to the screening chamber 20. Baffles 15 are mounted on or around rotor bearing housing 12 and project outwardly toward surface 104 of wall 11 through feed chamber 103 and also upwardly to or into screening chamber 20. Screening chamber 20 is defined by screen member or screen 30 which in this example is a right circular cylinder having a pattern of perforations 25 for selectively permitting passage of pulp slurry from screening chamber 20 through perforations 25 into accepts chamber 35 while retaining knots and other coarse particles. Screw conveyor flight 50 is supported by bracket arms 16 on rotor shaft 14. Screen 30 is joined to the outer edge of screw conveyor flight 50 s that the flight 50 and the screen 30 rotate together. Flight 50 is shown extending through about the upper three-fourths of the vertical height of screen chamber 20. Preferably, it may extend along one-half to three-fourths of the height of screen 30, although for certain applications, it will be continuous throughout the entire vertical height of screening chamber 20. In some cases it may only extend slightly into the topmost portion of the screening chamber. Above screening chamber 20, stationary housing extension 40 connects to liquid free knot discharge chamber 45. Flight 50 also extends to the knot discharge chamber 45 and rotates with its outer edge in close proximity to the inner surface 41 of stationary housing extension wall 43. On screen 30 in screening chamber 20, the pattern of perforations 25, open for the passage of pulp slurry from screening chamber 20 into accepts chamber 35, is configured to provide an imperforate surface 27 adjacent to and above the upper surface 51 of the flight 50 through which pulp slurry cannot flow from screening chamber 20 into accepts chamber 35, thus providing, in combination with the upper surface 51 of flight 50 two sides of a zone into and through which knots can be transported without being impeded or subjected to interrupted transport by drag forces and knot holding ability of the perforation entrances, a zone 55 of relatively increased tangential velocity and zero hydrodynamic screening forces on the knots. In addition, substantially vertical grooves 42 in the inner surface 41 of stationary housing extension wall 43 are shown. These grooves intermittently retard the rotary knot velocity. The knot transport enhancement features illustrated, thus, consist of baffles 15, surface 27 of zone 55 and vertical grooves 42 in housing extension 40 which, in combination, function to provide mechanisms to preclude interruptions in the passage of knots between the screening chamber 20 and knot discharge chamber 45.
The knot containing pulp slurry enters the knot drainer with a tangential velocity imparted to it by the tangential orientation of the inlet and the circular path of the inlet chamber 10. This motion is shown in the preferred embodiment as being in the same direction as the motion of screw conveyor flight 50 and screen 30 and, although consuming less power, if maintained into screening chamber 20, induces a lower relative (tangential) velocity between the screen 30 and the pulp slurry and knots. Drag generated by rotation of screen 30 also leads to a lower relative (tangential) velocity differential between screen 30 and the knot containing pulp slurry. The vertically projected surface 51 of flight 50 also tends to effect a lower relative (tangential) velocity between screen 30 and the pulp slurry and knots. In order for knots to be transported upward on flight 50 to knot discharge chamber 45, they must have a lower absolute tangential velocity than that of flight 50, i.e., have a relative velocity counter to that of flight 50. This will make possible the upward axial uninterrupted transport of the knots by transporting surface 51 into the top knot discharge chamber 45.
At different locations within the knot drainer, the knots are subjected to actions of differing forces. Starting from inlet chamber 10 the knots have a tangential velocity due to the orientation of the feed inlet. After passing under wall 11 and having lost substantially all of their tangential velocity due to the retarding effect of baffles 15 in feed chamber 103, the knots, being carried by the surrounding slurry, flow vertically upward into screening chamber 20. These baffles, shown in the preferred embodiment as being attached to bearing housing 12, are illustrated in more detail in FIGS. 2, 3A, and 3B. Note that FIG. 2 shows four baffles, but this is only an illustrative representation. The actual number of baffles 15 will be determined by consideration of size of the drainer 100, feed rate of the knot bearing slurry, consistency of the feed slurry, flocculating characteristic of the pulp, rotary velocity of the flight 50 and screen basket 30, number of screw flights 50, and pitch of screw flights 50. Thus, depending upon these considerations, the number, vertical height, and shape of the baffles 1 will be selected accordingly as necessary to arrest and/or retard the absolute tangential (rotary) velocity of the knot bearing pulp slurry in screening chamber 20.
Within screening chamber 20, it has been found that knot transport interruptions are attributable to flow of the fine fiber slurry through perforations 25 of screen 30, which flow tends to entrain knots, pull them tightly against, and hold them firmly on screen 30. Once knots are held stationary on screen 30 draining of pulp occurs around the knots with resultant packing of pulp fibers in the voids between knots, the whole culminating in a densely centrifuged relatively dry mass firmly held on to the surface of screen 30 which produces severe vibration and/or the screen 30 becomes unable to handle the feed flow which overflows into knot collection chamber 45 and the drainer must be shut down and the packed mass dug out. This holding and knot transport interruption tendency peaks adjacent to the upper (leading) surface 51 at the point of attachment of flight 50 to screen basket 30 if perforations 25 extend to the upper surface 51 of flight 50. This is amplified by and due to induced centrifugal force on the pulp slurry and knot mixture by flight 50 and is reinforced by the centrifugal action on the knots imparted by any tangential velocity which has not been dissipated by baffles 15. (Note that, adjacent to the perforated surface of screen 30 outside of imperforate area 27, some undesirable rotary flow velocity will be induced in the knot bearing pulp slurry due to the viscous drag exerted by the rotating screen 30, knot transporting flight 50, rotor shaft 14, and flight support bracket arms 16.) However, the induced rotary velocity of the knot containing pulp slurry, which will increase in magnitude with distance traveled up screen 30, must be relatively lower than that of the inside surface of screen 30. This difference in velocity causes knots to be tangentially "dragged" over perforations 25 in screen 30 on to surface 27 and into zone 55. The relatively lower velocity of the "dragged" knots with respect to the upper transporting surface 51 of flight 50 results in the upward transport of the knots by the spiral transporting upper surface 51 of flight 50 through the unimpeded free flow channel zone 55 in screening chamber 20 and into stationary housing extension 40. FIGS. 4, 5, and 6 illustrate the feature of the invention designed to eliminate the trapping and holding effect of the hydrodynamic screening forces which would otherwise result in knot transport interruptions in the screening chamber 20.
FIG. 4 shows a fragmentary schematic representation of the screen basket 30, its pattern of perforations 25, and surface 27 being one side of a zone 55 of reduced hydrodynamic screening forces. This is described as a locus defining a knot collecting and transporting zone, and because it indicates physical occlusion of certain of the perforations 25 of screen 30 in a pattern that conforms to the shape of spiralling upper surface 51 of screw conveyor flight 50. FIG. 5 shows the preferred embodiment of zone 55 which structurally consists of an unperforated band 27 of screen 30 extending upward from the attachment point of screw flight 50. This embodiment is preferred because it also saves the time and expense of drilling perforations 25 in the area of the unperforated band 27.
FIG. 6 shows an alternative embodiment which, for example, occludes existing drilled perforations 25, which permits retrofit of existing knot drainers, and/or replacement of screw flight 50, and modification of pitch of screw flight 50. In these cases, zone 55 is bounded by surface 27a of insert flange 52, a very thin band which extends upwardly from the attachment point of flight 50 along the surface of screen 30 to occlude a band of perforations 25 bounding zone 55. With the embodiments shown in FIGS. 5 and 6, knots being transported upward on flight 50 move smoothly along because, while on flight 50, they are no longer subject to the holding by hydrodynamic forces and drained fiber bonding attendant upon the flow of pulp slurry and/or liquid through the perforations 25 of screen 30 otherwise normally immediately adjacent to the transporting surface of flight 50. Thus, either unperforated band 27 or flange 52 can free the knots in the screening chamber 20 from the hydrodynamic forces which would otherwise trap and hold the knots at the juncture of the upper surface 51 of flight 50 and perforations 25 of screen 30.
Above screen chamber 20, spiral screw conveyor flight 50 extends through stationary housing extension 40. Flight 50 has no outside edge flange in this portion of the knot drainer. Housing extension 40 has one or more substantially vertical grooves 42 on its inner wall. These grooves 42 improve and have been found necessary to obtain uninterrupted vertical transport of the knots through the housing extension 40 and to avoid knot build-up, accumulation, and cessation of knot transport.
When travelling through housing extension 40 the knots or coarse particles are acted upon by gravity, the motion of the screw flight, friction with the housing extension wall, viscous drag of the liquid below liquid surface 65, and drain back of liquid above liquid surface 65. If the inner wall of housing extension 40 is smooth, or becomes smooth through wear, the circumferential friction forces between the coarse particles and the inner surface 41 of housing extension wall 43 will be of lower magnitude than the combination of gravity, knot frictional forces against the upper surface 51 of screw flight 50, viscous liquid drag, and liquid drain back above liquid surface 65. This will result in the coarse particles or knots remaining stationary with respect to the transporting surface 51 of screw flight 50 thereby sliding circumferentially around housing extension 40 at a constant elevation. Knot transport will thus cease and be interrupted, resulting in continued knot build-up with resulting out of balance vibration forces, screen perforation blockage, and interruption of production.
Even below liquid surface 65, before liquid drain back forces are present, the knots are subject to the viscous swirling action of the liquid which, coupled with the frictional forces between the knots and the screw conveyor flight 50, are sufficient to overcome the circumferential frictional forces between the knots and a smooth walled stationary housing extension 40. This also favors interruption of the knot transport on the screw conveyor flight 50.
FIG. 7 is a schematic representation of a portion of the knot drainer where the screening chamber 20 adjoins stationary housing extension 40. In this view, rotating screen, or screen basket, 30 is shown to have a pattern of perforations 25 as well as a surface 27 of occluded perforations and surface 51 of screw flight 50 generally designated as forming two sides of the zone 55 of reduced hydrodynamic screening forces. In stationary housing extension 40, two substantially vertical grooves 42 are shown as being oriented axially with the screw conveyor flight 50. Under most operating conditions, this orientation is acceptable, however grooves 42 oriented perpendicular to flight 50 would be functionally optimum because the orientation of grooves 42 parallel to the normal component of the force exerted on the knots by flight 50 would present the least resistance to transport of the knots toward the discharge chamber. It should be recognized, however, that the groove 42 orientation for maximum effectiveness will depend upon groove size, geometry, and spacing, operating speed of the knot drainer, inclination or verticality of the surface 41 of housing extension wall 43, and size and surface characteristics of the knots or coarse particles being processed as well as manufacturing costs. Thus, the favored orientation of grooves 42 will be determined by the totality of factors enumerated and, in one preferred embodiment of this invention four equally spaced axially oriented grooves have been found sufficient to enhance transport of both softwood and hardwood knots and to improve liquid/knot separation.
FIGS. 8A, 8B, and 8C are local cross sectional views as would be seen from reference lines 8A--8A, 8B--8B, and 8C--8C of FIG. 7 to illustrate three possible cross sectional configurations of grooves 42 in wall 43 of housing extension 40. FIG. 8C shows the preferred embodiment which allows for the smoothest continuous transport and the least opportunity for knot chipping and cutting or grinding action with flight 50. Only one cross sectional configuration of groove is used in any application and the three reference lines in FIG. 7 are used only for the sake of brevity.
In the operation of a rotary screen screw type knot drainer 100, knots are entrained in and carried by the flowing pulp/liquid mixture, and knot concentration reaches a peak at the exit of screening chamber 20. The force generated on the knots by fiber/liquid flowing through perforations 25 plus the centrifugal force on the knots combined with the knot holding tendency of the openings of perforations 25 all tend to reduce the desirable knot "sliding" on the perforated surface of screen 30 and hence negatively impact knot transport. Therefore, knot transport in screening chamber 20 is enhanced first by interposing baffles 15 in feed chamber 103 between inlet chamber 10 and transporting flights 50 in screening chamber 20. These baffles retard flow rate and reduce the tangential velocity of the feed slurry of knots, coarse particles, and fiber/liquid mixture. This reduces the magnitude of centrifugal force of the knots against screen 30 and increases the tangential velocity lag of the knots relative to the inner surface of screen basket 30, thus maximizing the speed at which the knots relatively "slide" circumferentially around the screen basket surface into the transport zone 55 on flight 50. Next, as the knot containing slurry passes through screening chamber 20, it encounters screw conveyor flight 50 which, because of its pitch and its relatively high rotary speed, lifts the knots upward along the surface 27 of screen 30 while simultaneously causing a gradual increase in the rotary velocity of the knot bearing slurry thereby creating a liquid vortex having an upper surface 65. Thus, between the bottom and the top of screening chamber 20, there is a gradient in rotary velocity of the pulp slurry and a corresponding gradient in the centrifugal force experienced by the pulp fibers and knots within the slurry. This centrifugal force tends to increase the flow rate of acceptable fibers through the perforations 25 of rotating screen basket 30. This same centrifugal force, however, increases the frictional arresting force between the knots or coarse particles and the edges of perforations 25 in the wall of screen 30. In addition, the hydrodynamic forces generated by the radially outward travel of fiber bearing liquid through perforations 25 of screen 30 tend to trap knots along with a quantity of fibers pinned between the knots and against the screen member 30. By occluding the perforations 25 along conveyor 50, in a path defining the zone 55 of reduced hydrodynamic screening forces, the effective frictional forces and holding tendency between the knots and the wall of screen 30, are eliminated, and concentrated knot transport is thus enhanced through screening chamber 20. Most of the acceptable fiber passes through the perforations 25 of screen basket 30, and, as a consequence, when the knots enter housing extension 40, they are relatively fiber free. Washing by nozzle 110 releases the remaining fiber from the knots, and the wash liquid and released fiber flow down the vortex for discharge through perforations 25.
The viscous drag exerted by the relatively fiber free liquid on the knots is significantly lower than that exerted by the pulp slurry at the inlet. The uninterrupted knot transport between the screen 30 and wash liquid separating housing extension 40 is accomplished and continued through the housing extension 40 by the significant knot circumferential arresting force attributable to the substantially vertical grooves 42 in the wall 43 of housing extension 40, which is sufficient to maintain the motion of and, depending upon the groove cross sectional configuration and angle, accelerate the knots and coarse particles up conveyor flight 50 and into liquid free knot discharge chamber 45.
As in any case where reactions are initiated, accelerated, retarded, or stopped by a change in balance between opposing forces, it should be remembered that increasing forces on one side of the balance is equivalent to decreasing forces on the other side, and vice versa. Substantially vertical grooves could also be replaced by ridges or a combination of grooves and ridges to cause the same increase in the circumferential friction component; however, such ridges would promote grinding and binding of knots and be detrimental to the performance of the drainer and the quality of accepted knot free pulp. Thus, it will be obvious to any person skilled in the art that the perturbations in force balances discussed herein represent only one example of numerous methods for accomplishing the same result. | A method and apparatus for enhancing knot transport in a knot drainer has a provision for decreasing tangential velocity of the feed slurry in the inlet chamber, a hydrodynamic force reduction provision in the screening chamber, and a provision for increasing the ratio of circumferential friction forces to axial friction forces in a housing extension above the screening chamber. This drastically reduces frequency of knot transport interruptions which would otherwise occur in the knot drainer, thereby improving knot drainer performance efficiency. | 3 |
SUMMARY OF THE INVENTION
The invention herein relates to a purse split insert for insertion in a purse having two separated compartments as well as in a purse having a single compartment. First insert means is provided having an exterior wall, an interior wall and opposing collapsible end walls. The exterior and interior walls have lower edges thereon and are joined together at the lower edges. Further, the first insert means has opposing sides which are connected by the opposing collapsible end walls which extend therebetween and thereby form an upper opening in the first insert means. Inside and outside surfaces are present on the first insert means exterior and interior walls. A plurality of flexible sheet-like members have lateral and lower peripheral edges and lie alongside and adjacent to portions of the exterior wall inside and outside and the interior wall inside surfaces. Means is provided for attaching the flexible sheet-like members at the lateral and lower peripheral edges to the adjacent portions of the exterior wall inside and outside and the interior wall inside surfaces to form a first plurality of upwardly opening article receiving pockets which are accessible at the first insert means exterior wall outside surface as well as through the first insert means upper opening. Second insert means has an exterior wall, an interior wall and opposing collapsible end walls. The latter exterior and interior wall have lower edges thereon and they are joined therealong. Further, the exterior and interior walls have opposing sides which are connected by the last mentioned opposing collapsible end walls to thereby form an upper opening in the second insert means. Inside and outside surfaces are present on the second insert means exterior and interior walls. A plurality of flexible sheet-like members having lateral and lower peripheral edges lie alongside and adjacent to portions of the exterior wall inside and outside and the interior wall inside surfaces. Means is provided for attaching the lateral and lower peripheral edges to the adjacent portions of the exterior wall inside and outside and the interior wall inside surfaces to thereby form a second plurality of upwardly opening article receiving pockets which are accessible at the second insert means exterior wall outside surface as well as through the second insert means upper opening. Releasable means is provided for attaching the first insert means interior wall outside surface to the second insert means interior wall outside surface. As a result, engagement of the releasable means facilitates insertion of the purse split insert in the purse having a single compartment and release thereof facilitates insertion in the purse having two separated compartments.
A purse split insert is disclosed which is insertable into first and second purse compartments within a split compartment purse and into a sole compartment within a single compartment purse. A first purse insert has a first exterior wall which has a lower edge and opposing lateral edges. A first interior wall is present on the first purse insert wherein the first interior wall has a lower edge and opposing lateral edges. A first pair of expandable opposing end walls is also present in the first purse insert. The first exterior and interior walls are joined at the lower edge and the first pair of expandable opposing end walls are attached to and extend between the first exterior and interior walls at the opposing lateral edges so that an upper opening is formed in the first purse insert. A second purse insert has a second exterior wall which also has a lower edge and opposing lateral edges. A second interior wall is present on the second purse insert wherein the second interior wall also has a lower edge and opposing lateral edges. A second pair of expandable opposing end walls is also present on the second purse insert. The second exterior and interior walls are joined at the lower edges and the second pair of expandable opposing end walls are attached to and extend between the second exterior and interior walls at the opposing lateral edges. In this fashion an upper opening is formed as well in the second purse insert. Releasable means are provided for attaching the first interior wall to the second interior wall so that the first and second purse inserts are selectably joined together and separated for insertion within a single compartment purse and within a split compartment purse, respectively.
A purse split insert is provided for placement as separate inserts within separate purse compartments in a split compartment purse and as a unitary insert within a single compartment in a single compartment purse. A first folded continuous member has opposing lateral sides and ends positioned in spaced side by side relationship. First means is provided for joining the opposing lateral edges whereby a first upper opening is formed between the first folded continuous member spaced ends. A second folded continuous member is provided having opposing lateral edges and ends positioned in spaced side by side relationship. Further, second means is provided for joining the opposing lateral edges, whereby a second upper opening is formed between the second folded continuous member spaced ends. Releasable means is provided for attaching the first and second folded continuous members together so that the first and second upper openings are in adjacent side by side relationship.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a section through a split compartment purse showing the purse split inserts of the present invention in place.
FIG. 2 is a section through a single compartment purse showing the purse split insert of the present invention in place.
FIG. 3 is an end view of one insert in the purse split insert.
FIG. 4 is an end view of another insert in the purse split insert.
FIG. 5 is an isometric of the purse split insert of FIG. 3.
FIG. 6 is a section along the line 6--6 of FIG. 3.
FIG. 7 is a section along the line 7--7 of FIG. 4.
FIG. 8 is a section along the line 8--8 of FIG. 4.
FIG. 9 is an isometric of the purse split insert of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Ladies' purses are generally coordinated with other articles of ladies' dress, whereby it is not uncommon for several purses to be included in a lady's wardrobe. It therefore becomes necessary to shift articles commonly carried in a purse to a different purse when a change in attire requires it. The invention to be described herein is intended to facilitate the shifting of commonly carried articles from one purse to another purse.
With reference to FIG. 1, a split compartment purse 10 is shown in section wherein the purse has an outer wall 11, a pair of end walls (one of which is shown as item 12 in the section of FIG. 1), a bottom wall 13 and an opposing wall 14, thereby creating an upper opening in the purse 10. A closure flap 16 extends from the upper portion of the opposing wall 14 having one portion of a snap fastener 17 mounted on the inside surface thereof. The closure flap 16, when placed over the upper opening shown in the purse 10, brings the portion 17 of the snap fastener into contact with a mating portion 18 of the fastener for securing the closure flap in place over the upper opening. A carrying strap 19 for the hand, arm or shoulder is shown extending from the end wall 12 in FIG. 1. A separator wall 21 is shown inside the purse 10 which separates the interior of the purse into two compartments shown as 10a and 10b in FIG. 1. A left purse split insert 22 is seen within the compartment 10a and a right purse split insert 23 is shown within the compartment 10b of split purse 10. It may be seen in FIG. 1 that the split inserts 22 and 23 are separated from one another by the separator wall 21.
Turning to FIG. 2, a purse 24 is shown having a wall 26, a pair of end walls (one of which is shown in the section of FIG. 2 as item 27), and a bottom wall 28. An opposing wall 29 is shown, from the upper portion of which extends a closure flap 31. One portion of a snap 32 (or other fastening means) is shown on the inner surface of the closure flap 31 so that the closure flap may be positioned over the upper opening shown in the purse 24 and come into engagement with a mating part 33 of the snap mounted on the wall 26 of the purse 24. Again, a strap 34 is shown for carrying the purse 24 by hand, over the arm or over the shoulder. The purse split inserts 22 and 23 are seen within the single compartment in the purse 24 in contact with one another along one wall thereof and fastened together in a fashion and by means which will be hereinafter described .
One portion of the purse split insert described herein is seen in FIG. 3 as the insert 22. Insert 22 has an exterior wall 36 and an interior wall 37. The exterior and internal walls 36 and 37 run into and out of the paper as seen in FIG. 3, having lateral edges, one of which is visible in FIG. 3. Expandable/collapsible end walls, one of which is shown at 38 in FIG. 3, extend between the opposing lateral edges of exterior and interior walls 36 and 37 of insert 22. Consequently, an upper opening is formed in insert 22 which is selectively opened and closed by moving the upper reaches of walls 36 and 37 toward and away from each other. The end walls, represented by item 38, are made of a relatively flexible fabric, while the exterior and interior walls 36 and 37, respectively, are fabricated from a stiffer fabric. Mating fastener pairs 39a and 39b are positioned on the inside surfaces of the upper reaches of walls 36 and 37 so that the upper opening in the insert 22 is held in a closed position by the mating fastener pairs when the upper ends of the walls 36 and 37 are moved together.
Turning now to FIG. 4 of the drawings, the purse split insert 24 is seen having an interior wall 41, an exterior wall 42, and expandable/collapsible end walls, one of which is shown at 43 in FIG. 4. As described in connection with insert 22, the walls 41 and 42 of insert 23 are fabricated from a relatively stiff material, while the end walls represented by item 43 are made from a thinner material with less stiffness. As a result, the interior and exterior walls 41 and 42, respectively, of insert 23 may be moved together or spread apart to vary the size of an upper opening therein. Once again, when the upper portion of the internal and external walls of the insert 23 are moved together until they are in contact, pairs of mating fasteners shown as items 44a and 44b are engaged to maintain closure of the upper opening.
Both of the inserts 22 and 23, as shown in FIGS. 3 and 4, display joinder of the external and internal walls 36 and 37 of insert 22 and the external and internal walls 42 and 41 of the insert 23 at the lower portions thereof. The exterior and interior walls of the inserts 22 and 23 are perceived in one form to be fabricated of a continuous wall member which extends from the upper portion of the interior wall past the lower portions of the walls to the upper portion of the exterior wall. In this fashion, the exterior and interior walls of each of the inserts are formed by a folded continuous member, with the ends of the member in spaced apart relation when the insert upper opening is opened. Alternatively, each of the interior and exterior walls of each insert may be fabricated from separate wall members having lower edges which are joined together, as by sewing, to form interior and exterior wall combinations as shown in FIGS. 3 and 4.
In FIG. 3, at an upper position and at a lower position on the interior wall 37 a portion of a fastener 46 such as a strip of Velcro™ is seen affixed to the internal wall. As seen in FIG. 4, in corresponding upper and lower positions on the interior wall 41, mating portions 47 for the fastener portion 46 are seen affixed to the interior wall. The fastener portions 46 and 47 could as well be snaps or any other suitable releasable fastening means. In this fashion, the interior walls 37 and 41 of inserts 22 and 23, respectively, when placed in contact are held in side by side position by the mating features of the fastener portions 46 and 47.
It may be seen that when the mating portions of the fasteners 46 and 47 are engaged, the purse split insert portions 22 and 23 are held together by the fasteners and the unitary combination of the purse split insert is insertable within the single compartment of purse 24 as seen in FIG. 2. When the purse split insert of the present invention is to be used in a split compartment purse such as purse 10 in FIG. 1, the fastener portions 46 and 47 seen in FIGS. 3 and 4 are released and the inserts 22 and 23 are individually placed within the separated compartments 10a and 10b, respectively, as shown in FIG. 1. It should be noted that in FIGS. 1 and 2 the inserts are shown with the upper opening fasteners 39a/39b and 44a/44b engaged so that the upper openings in each of the inserts 22 and 23 are closed.
Turning now to FIG. 5 in the drawings, an isometric of the insert 22 is shown. The inside surface of interior wall 37 is designated 37b in FIG. 5. The inside surface 37b is divided into two halves by a sewn member 45 attached to the inside surface. A pair of slant top pockets 50 and 48 are formed between the sewn member 45 and the collapsible/expandable end wall designated 38b in FIG. 5. The pockets 50 and 48 occupy the left side of the inside surface 37bin FIG. 5 and are formed by sewing the lateral and lower peripheral edges of a piece of sheet-like fabric in place leaving the upper peripheral edge open. In this fashion upper openings 50a and 48a are provided in the pockets 50 and 48.
On the right side of the inside surface 37b of interior wall 37 as seen in FIG. 5, a plurality of sheet-like pieces of fabric are sewn between the sewn member 45 and the expandable/collapsible end wall 38 at stepped heights on the inside surface. The number of sheet-like members 49a, 49b, 49c and 49d are also sewn at the lower peripheral edges to the inside surface 37b to form upwardly opening pockets for receiving items such as credit cards, etc.
The outside surface of exterior wall 36 as seen in FIG. 5 has sheet-like members 51, 52 and 53 sewn thereto at the lateral and lower peripheral edges thereof to form respectively a slant top pocket having an opening 51a, a pen or other tubular article receiving pocket having an upper opening 52a, and an additional pocket having an upper opening 53a.
FIG. 6 shows the inside surface 36a of exterior wall 36. The portions of the upper opening closure fasteners 39a are shown near the upper edge of the inner surface 36a. A strip of bias tape 54 is seen running down the lateral edges of the exterior wall 36 in FIG. 6 which when sewn in place along the lateral edges fixes the edges of the collapsible/expandable end walls 38 and 38b to the inside surface 36a of the exterior wall 36 at either lateral edge thereof. Further, a sewing operation at the lateral edges of exterior wall 36 secures one edge of slant top pockets 56 and 57 to the inside surface 36a of exterior wall 36. The opposing edges of the slant top pockets are secured to the inside surface 36a by a sewn member 58 running from the upper to the lower portion of the inside surface 36a. The slant top pockets 56 and 57 have upper openings as shown at 56a and 57a.
FIG. 7 shows the outside surface of interior wall 41 and the mating portions 47 of the fastening combination 46/47 which affixes inserts 22 and 23 together in releasable fashion. It should be noted in FIG. 7 that the fastener portions 47 are depicted as Velcro™ strips. Velcro™ is a known "loop and hook" type fastener. The fastener portions could as readily be portions of snap type fasteners. In such a case a corresponding pattern of matching portions of snap type fasteners would be affixed to the outside surface of interior wall 37 in insert 22. FIG. 7 further shows a bias tape 61, similar to bias tape 54 in FIG. 6, which is sewn along the lateral edges of interior wall 41.
FIG. 8 shows an inside surface 42a of the exterior wall 42 in purse split insert portion 23. The bias tape 61 strip is shown attached to the lateral edges of the exterior wall 42 serving to hold the expandable/collapsible wall 43 in place at one side of the insert and an opposing expandable/collapsible end wall 43b in place at the opposing side of the exterior wall 42. A sewn member 62 is shown extending from the upper edge of exterior wall inside surface 42a toward the lower edge thereof. Sheet-like members 63 and 64 have lateral and lower peripheral edges which are sewn, and therefore fixed to the inside surface 42a in conjunction with affixing the bias strips 61 in place and the affixing of the sewn member 62 in place. An upper slant top opening 63a provides access to an upwardly opening pocket thus formed by sheet-like member 63. In like fashion, an opening 64a provides access to a pocket thus formed by the sheet-like member 64.
FIG. 9 is a perspective of the purse split insert portion 23 wherein the outside surface of exterior wall 42 and the inside surface 41a of interior wall 41 are visible. Expandable/collapsible end walls 43 and 43b are shown in partially closed or collapsed condition. Inside surface 41a has a sewn member 66 extending from the upper to the lower portions of the inside wall which serves to fix one edge of a sheet-like member 67 to the inside surface. The opposing side of the sheet-like member 67 is affixed to the inside surface 41a at the same time and by the same means for affixing the bias tape 61 and one edge of the expandable/collapsible wall 43b to the inside surface. The lower peripheral edge of the sheet-like member 67 is also fixed to the inside surface 41a as by sewing or through the use of an adhesive or the like. As a result, the sheet-like member 67 forms a pocket with an upper opening 67a therein. The opening 67a has a cover flap 68 attached to the inside surface 41a immediately thereabove. A fastener portion 69a is attached to the inside surface of the cover flap 68 which, when the flap 68 is lowered, is brought into contact with a mating fastener portion 69b attached to the outer surface of the sheet-like member 67. In this fashion a closure cover is provided for the opening 67a to allow articles to be deposited through the opening 67a into the pocket when the flap 68 is raised and to secure the articles within the pocket when the fastener portions 69a and 69b are brought into engagement. The fastener portions 69a and 69b may be closure devices such as snap fasteners as shown in FIG. 9. Further sheet-like members 71 and 72 are secured at the lateral edges thereof by the sewn member 66 and the bias tape 61 adjacent the expandable/collapsible end wall 43 on insert 23. The sheet-like members 71 and 72 have their lower peripheral edges fixed to the inside surface 41a in FIG. 9. As a consequence, openings 71a and 72a are provided which allow articles to be inserted therethrough and retained within pockets formed by the inside surface 41a and the sheet-like members 71 and 72.
With further reference to FIG. 9, a fabric sheet 74 is depicted having its lateral edges secured to the outside surface of exterior wall 42 by the bias tape 61 at opposing lateral edges of the exterior wall. An upwardly-oriented opening 74a which extends across the width of the exterior wall 42 is thereby formed for receiving and storing larger flat articles therein. Another sewn member 76 extends from the opening 74a to the lower portion of the exterior wall 42. Sheet-like members 77 and 78 are fixed at their adjacent lateral peripheral edges by the sewn member 76 and at their opposing lateral edges by the bias tape 61 fixed to the opposing lateral edges of the insert 23. Sheet-like members 77 and 78 are secured across their lower peripheral edges to the outside surface of the exterior wall 42. A pair of pockets are thereby formed on the outer surface of the sheet-like member 74 having upwardly extending openings 77a and 78a therein.
It may be seen from the foregoing that a purse split insert has been disclosed which is useful in split compartment or single compartment purses and which readily conveys articles generally contained within a purse from one purse to another regardless of purse type.
Although the best mode contemplated for carrying out the present invention has been shown and described herein, it will be understood that modification and variation may be made without departing from what is regarded to be the subject matter of the invention. | A split insert pair for a purse is made of fabric which is stiffer at the outside walls and less stiff at the end walls and which has an upper opening which is capable of either being opened wide or held in closed position by fasteners located on opposite sides of the upper opening. Various upwardly opening pockets are situated on the inside and outside surfaces of the insert walls to receive the usual articles carried in a purse. An outside wall on each of the inserts of the pair is provided with matching patterns of releasable fasteners, so the pair of inserts is useable as a unitary joined pair or as separate inserts which may be placed in separate purse compartments. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/413,967, 2010 Filed Nov. 15, 2010.
FIELD
[0002] The following description relates generally to natural gas recovery, and more particularly to a method for identifying highly productive locations for hydrocarbon extraction from black shale.
BACKGROUND OF THE INVENTION
[0003] Driven by geopolitical and hydrocarbon reserve uncertainties and the continuously increasing real cost of energy, domestic energy production is necessary to ensure the energy security and independence of the United States. In order to meet these increasing energy demands with domestic production, unconventional energy resources such as shale gas, shale oil and alternative coal technologies must be increasingly utilized. Economically viable production of unconventional energy resources requires enhanced methods of oil and gas recovery such as hydraulic fracturing and horizontal drilling.
[0004] The combination of these techniques has had mixed success at extracting economic quantities of natural gas from low permeability shale deposits, which have poor country rock permeability and transmissivity, but can contain natural fractures. Hydraulic fracturing involves the injection and extraction of fluids and propping agents in the subsurface to stimulate fluid flow through natural fractures and increase fracture related permeability (e.g. increased fracture aperture, fracture size, and fracture network connectivity) thus enhancing hydrocarbon production. The use of hydraulic fracturing is limited by: 1) inefficient resource recovery, 2) the potential for groundwater contamination from drilling fluids or mobilized hydrocarbons that can migrate through fractures and interact with groundwater, and 3) the current inability to develop accurate models for fracture fluid flow in the exceedingly complex fracture network present in black shale and other fractured lithologies. Therefore successful, economically viable, and environmentally safe application of these techniques requires a detailed understanding of fluid transport within the subsurface, specifically fluid flow within fracture networks.
[0005] Accordingly, there is a need for improved strategies for hydrocarbon extraction. The embodiments of a predictive methodology for directly evaluating fluid flow through natural and stimulated fractures in situ by integrating noble gas geochemistry, trace element geochemistry, and fracture analysis, disclosed below, satisfies this need.
SUMMARY
[0006] The following simplified summary is provided in order to provide a basic understanding of some aspects of the claimed subject matter. This summary is not an extensive overview, and is not intended to identify key/critical elements or to delineate the scope of the claimed subject matter. Its purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.
[0007] Black shales are of great interest as domestic hydrocarbon plays because of their high organic content and tight gas-retaining nature. Although market demand is increasing interest in shale hydrocarbon extraction, the present inventor is unaware of any comprehensive methodology capable of identifying highly productive areas known as “sweet spots” because of a paucity of information about geological fracture-related fluid flow. Because of the immense costs associated with horizontal drilling and hydraulic fracturing, as well as the risk of environmental impact, hydrocarbon recovery from unconventional sources, such as black shale, is not economically favorable unless wells hit a sweet spot. By directly evaluating natural fluid migration in situ using conservative noble gas diffusion profiles, trace element proxies for geological fluid flow, and the characteristics of the fracture network, the presently disclosed predictive model for natural gas migration and determination of the location of sweet spots in shale has been developed. The present invention will directly contribute to a comprehensive strategy for hydrocarbon extraction, specifically in regions which lack deformed structures that lead to bed thickening shale and increased fracturing. In addition, because its techniques directly monitor fracture fluid migration on multiple geologic scales, the present invention allows for the evaluation of risk for aquifer contamination from hydraulic fluid and shale gas.
[0008] The present invention comprises a combination of methods. Noble gas abundances and isotopic ratios (He, Ne) and trace element geochemistry (transition metals (Ti, Mn, Fe), rare earth elements (La—Lu), actinide chemistry (Th/U)) with advanced techniques in fracture network analysis are integrated, in order to: 1) determine the multi-stage fluid flow history through individual fractures; 2) quantify gas diffusion from relatively impermeable hydrocarbon host rock (i.e. black shale) to fracture sets; 3) develop a 3-D geospatial map of the regional fracture network to determine pathways of fluid migration; and 4) map chemical changes for the development of a regional hydrocarbon “sweet spot” map.
DETAILED DESCRIPTION
[0009] Preliminary research focused on the New York State portion of the Marcellus shale because of its potential for hydrocarbon production and because the naturally fractured black shale provides an optimal location for describing in detail the claimed methodologies. A short synopsis of the current state of hydrocarbon production in the Marcellus shale, a review of fracture-related fluid flow, fracture network analysis techniques, and relevant geochemical proxies are presented below.
Regional Geology
[0010] The Marcellus shale in New York is located on the Appalachian plateau and is in the foreland of the Appalachian Fold Thrust Belt. It lies to the North and West of the Valley and Ridge province and is characterized by salt-detachment tectonics. The first order deformation structures of the Appalachian plateau are detachment folds, which have a basal decollement in the Silurian-aged Salina Salt. This salt layer acts as the glide plane for the Appalachian plateau detachment sheet and causes surface features characteristic of salt tectonics such as broad, gentle folds and abrupt changes in deformation style at the lateral and frontal termination of the salt. Salt also plays a role in faulting. Salt is thickened in the hinges of detachment anticlines and provides a weak zone that is easily faulted, resulting in blind reverse splays that cut up from the decollement in the salt and slice through this weak core.
[0011] The stratigraphy of the Appalachian plateau varies, but in New York the Marcellus shale is the stratigraphically lowest subgroup of the siliciclastic Devonian Hamilton group. The Hamilton group is sourced from the Acadian orogeny and Rb-Sr dating of the lower Devonian black shales in the Hamilton groups puts their age at 384±9 to 377±11 Ma. The Hamilton group is sandwiched between the overlying late Devonian Catskill deltaic sequence and the underlying clean carbonates of the Devonian Onondaga limestone. The Marcellus subgroup is comprised of three formations: 1) the Union Springs-the lowest stratigraphic black shale unit; 2) the Oatka Creek Formation-the highest stratigraphic black shale; and 3) its lateral stratigraphic equivalent, the Mount Marion Formation. The Union Springs formation is made of black shales and dark grey limestones, and is separated from the black shales of the Oatka Creek and Mount Marion formations by the Cherry Valley limestone.
[0012] The Appalachian plateau was deformed during the Pennsylvanian-Permian Alleghany orogeny. During this event, deformation progressed from the hinterland to the foreland along the basal salt layer. The Appalachian Plateau detachment sheet progressed to the northwest during this orogeny and did not interact with the underlying basement. Deformation within the detachment sheet varies with stratigraphy; in the lowermost strata shortening was accommodated by low-angle thrust faulting, while at higher levels shortening was first taken up by layer-parallel shortening and then accommodated by broad folding. In all, Alleghanian deformation occurred during two progressive stages: layer parallel shortening occurred first and was followed by a period of detachment folding and reverse faulting.
[0013] The first stage of deformation, layer parallel shortening, is expressed in surficial geology by the deformed fossils and solution cleavage. Strains of up to 20% are observed in fossils and both solution cleavage and fossil shortening indicates a strain ellipsoid that has its short axis perpendicular to the regional structural trend. Solution cleavage maintains its bed-perpendicular orientation around folds and confirms that cleavage formed before folding.
[0014] During the second stage of deformation, detachment folds formed by buckling above the Salina salt. These folds are characterized by comparatively tight anticlines cored by salt and broad synclines (FIG. 3). The cores of folds are significantly tighter in the salt horizon, but at higher stratigraphic levels folds are open with very gently dipping limbs (<5 degree limb dips). Folds are slightly asymmetric with steeper southeastern limbs. Thrust splays cut up from the decollement through the weak anticlinal fold-cores but do not make it to the surface and both antithetic and synthetic faults are common.
[0015] Fracturing is a pervasive and complex feature of the Appalachian plateau that developed during successive phases of the Alleghanian orogeny and is associated with the first order structures. Fractures can be grouped into sets by their orientation, but the relationships between these sets are not completely understood. N-S striking fractures are interpreted as extension fractures due to early E-W extension in the forebulge of the Alleghanian orogeny. Cross-fold fractures (strikes ranging from 012° to 327° are difficult to interpret; explanations vary from fracturing due to multiple phases of the Alleghanian orogeny, to fracturing due to the stress field before the Alleghanian orogeny or tectonic unloading after the orogeny, or a combination of these mechanisms that invokes reactivation of fractures. ENE-striking fractures(˜071°) are interpreted as neotectonic and due to overpressure caused by hydrocarbon generation.
[0016] During Alleghanian tectonics, fluids migrated to the Appalachian plateau from the Appalachian fold-thrust belt, with the hypotheses for the driving force ranging from a mechanical “squeegee” to a thermally driven mechanism. This fluid migration caused a widespread resetting of the magnetic signatures in the rocks, suggesting regional-scale fluid flow. This regional fluid flow utilized fractures within the Marcellus shale and is recorded in the geochemistry of the country rock and veins. Although the natural gas found in the Marcellus shale formed in place, this regional fluid flow caused the transport of fluids through fractures and is evidence of past fluid flow through the fracture network. This fluid flow may have altered gas concentrations in the Marcellus, and quantifying these changes can serve to define a model for understanding gas recovery through induced fracturing (eg. hydraulic fracturing)
[0017] Hydrocarbons can be created through biogenic and thermogenic means, with biogenic processes being significant at shallow depths and thermogenic production dominating at deeper levels. Significant hydrocarbon generation is usually attributed to a thermogenic process; hydrocarbons are formed at depth from the thermal degradation of kerogen. As rock is buried, temperature and pressure increase and the structure of kerogen becomes unstable. Kerogen progressively adjusts to this increasing temperature and pressure by eliminating functional groups and the linkages between nuclei, thus generating a wide range of compounds including hydrocarbons, CO 2 , Water, and hydrogen sulfide. Additionally, natural gas comprised of methane, ethane, propane, and n-butane (C1, C2, C3, and C4, respectively) can be generated through the mechanism of transition-metal catalysis. Laboratory efforts to generate gas by purely thermal mechanisms show higher formation temperatures than observed in nature (up to 400° C.) or result in a higher fraction of heavy gasses (C2-C4) than seen in nature. However, a catalytic mechanism produces gas at low temperatures (□200° C.) with C1—C4 fractions that mimic natural gas. In particular, marine shales (such as the Marcellus shale) show an increase in released light hydrocarbons over time, indicating the opposite effect of traditional desorption. These shales generally contain the necessary transition metals for catalytic gas generation and the Marcellus shale is no exception.
Hydrocarbon Production in the Marcellus Shale
[0018] Within the last 5 years interest in natural gas production from the Marcellus shale has spiked because of the development of enhanced recovery technologies. Although there is current drilling for natural gas in the Marcellus shale in Pennsylvania, permitting issues have stalled work in New York. Current drilling efforts in Pennsylvania are focused on the hinges of anticlines where the Marcellus is thickened and where fracturing is most intense, but this strategy is not viable in New York because deformation towards the east is weaker and large scale geologic structures (e.g. folds) are more subtle. Despite political delays and geostructural challenges, there is interest in drilling in New York. The lack of structural controls and an insufficient understanding of fracture fluid flow necessitate more research in order to ensure efficient and safe production of natural gas. The lack of recent exploration in the NY Marcellus shale makes the present invention both timely and useful. With sufficient data, the present invention can develop reservoir-, field-, and regional-scale interpretations of fluid flow without the need for extrapolation; this makes the present predictive technology especially useful to local inhabitants, state governments, and hydrocarbon extractions corporations when implemented in the early stages of exploration.
[0019] In addition to the appropriate timing for evaluation and increasing resource demands, the Marcellus shale offers logistical advantages that make it an excellent case study. For example, it is exposed in many quarries across New York State based on its stratigraphic position above the quarried Onondaga limestone. This coincidence allows study of the three-dimensional relationships of fractures with great accuracy, and sampling of fresh, unaltered, outcrops that are revealed through quarrying activities. These outcrops are not weathered and their geochemistry is preserved, making them a useful analogue for more deeply buried rocks.
[0020] Some economically important geological advantages to studying the Marcellus shale in New York are the type of deformation, the amount of deformation, the fracture pattern, and the regional fluid flow that this area experienced. Compared with the intensely deformed sections of the Marcellus shale in the Valley and Ridge province of Pennsylvania, the Marcellus shale in New York is relatively undeformed and fracture patterns have not been overprinted by larger structures. This lack of deformation in Appalachian plateau region of the Marcellus prevented the thickening and increased fracturing of shale beds, making it very difficult to determine the best location for extraction wells and predict the location of highly fractured “sweet spots”. This necessitates the understanding of fracture related flow in the plateau section of the Marcellus shale for any drilling program.
Static Conductivity, Fractures, and Hydrocarbon Flow
[0021] Fractures are surfaces in rock along which mechanical failure has occurred and the rock has lost cohesion. They can form in tension (mode 1) or shear (mode 2 or 3) and often form sets of similarly oriented members. Fractures that accommodate some degree of slip along their surfaces are faults, while fractures that have no observable slip are joints. A grouping of fractures with sub-parallel orientations is a fracture set, while all of the fractures regardless of orientation form the fracture network.
[0022] Because black shale (country rock) is the ultimate source of hydrocarbons, the rate at which hydrocarbons diffuse into fractures and flows through the fracture network limits hydrocarbon production. The rate of hydrocarbon diffusion into fractures and through the fracture network is controlled by the hydraulic conductivity of the system (K). Hydraulic conductivity is a function of a rock's bulk porosity and permeability and describes the ease with which a fluid is transported through pore spaces or fractures.
[0023] In black shale, the extractable volume of hydrocarbons is directly proportional to the system's hydraulic conductivity (hereafter: K), which is a factor of 1) the hydraulic conductivity of the country rock (K CR ) and 2) the fracture network (hereafter: K FN ). Thus fluid flow is simultaneously affected by K CR and K FN and their interaction (Eaton, 2006). In areas that have low country rock permeability (i.e. shales), flow properties are dominated by fractures, while fractures are less important in areas with higher country rock permeability (e.g. sandstones). As hydrocarbons diffuse from the country rock into fractures, the hydraulic conductivity of the fracture network (K FN ) is directly related to the characteristics of the individual fractures, fracture sets, and the entire fracture network.
Individual Fractures
[0024] Size, location, termination style, aperture, planarity and roughness are key characteristics to determine flow within individual fractures. The size of a fracture refers to the three-dimensional surface area of the fracture, while aperture is the openness of fracture planes. Planarity (a measure of a fracture's deviation from a plane) and roughness (planar tortuosity) are important factors in determining permeability. The termination style defines the geometric orientation of the end of a fracture. There are four types of terminations including: T—a perpendicular intersection between fractures; J—an intersection in which one fractures curves into the other; I—a fracture that ends at its tip line without intersection and X—cross-cutting fractures. Combinations of these termination geometries and the location of individual fractures define the 3-D geometry of a fracture network. All of the above parameters influence hydraulic conductivity (i.e. the amount of hydrocarbons that can migrate through the fracture) and each other. For example, permeability and porosity concomitantly increase with increasing country rock grain size and fracture size, and the statistical probability of fracture intersection (connectivity) also increases with larger fracture size. Fracture connectivity, porosity, and permeability all affect hydraulic conductivity implicating a complex relationship between K FN and fracture properties.
Fracture Sets and Networks
[0025] Fractures are grouped by their geometry into fracture sets or groups of sub-parallel oriented fractures. Orientation and spacing of fracture sets in a network are characteristics that affect fluid flow in different ways. For dense and homogeneous fracture networks fluid flow can be treated as flow through a porous medium, while in sparsely fractured areas a few large fractures may dominate flow. Fracture network hydraulic properties depend on fracture intensity (surface area of fractures per unit volume), connectivity (number of fracture intersections per unit volume), hierarchy, and chronology.
Critical Dynamic Parameters Impacting Fracture Regulated Fluid Transport
[0026] Modeling the migration of hydrocarbons in fractured black shales is exceedingly complex due in part to the complex nature of hydraulic conductivity in a fractured medium, but also to the many dynamic processes of the earth. For example, dynamic changes in parameters such as regional stress field, in fracture mineralization, fluid pressure, climatic changes (wetness/dryness), fluid gradient, anthropogenic water use, and tectonic processes reduce the accuracy of model inputs significantly and retard the understanding of fluid transport through fractured media.
[0027] Most importantly, even at great depths under high overburden pressures, fractures must be open in order to accommodate fluid flow. How fractures remain open (aperture>0) and the relative importance of mechanical and diagenetic characteristics in keeping fractures open is still contentious. Some authors argue for the role of the in situ stress field and suggest that only fractures oriented parallel to the maximum compressive stress will stay open and accommodate fluid flow. Fractures may never completely close if there is a sufficient hydraulic gradient, even though permeability decreases significantly as stress normal to the fracture increases. In addition, some component of shearing can keep fractures open, causing asperities on opposite faces of the fracture to ride up over one another and prop open the fracture.
[0028] The diagenetic approach to finding open fractures focuses on mineralization within open fractures and country rock stiffening due to cementation. Mineral bridges can form in fractures and cement can precipitate in the host rock holding fractures open regardless of fluid pressure or stress field changes. In the Travis Peak formation in East Texas, fluid inclusions were used to reconstruct the temperature and pressure of vein formation. Burial models suggest a 48 Myr history of vein growth, indicating that fractures were open and slowly grew minerals for an extended period of time. However, mineralization does not necessarily lead to increased permeability through fractures since complete mineralization can cause fractures to close. For example, the hydrocarbon-rich Barnett Shale of Northern Texas has fault induced fractures, but drill cores show pervasive calcite veining which correlates with low hydrocarbon production in heavily fractured areas and suggests that fractures can be completely sealed by mineralization. Past research indicates that partially mineralized fractures have the greatest potential to stay open, but fracture type and geometry as well as hydraulic gradient can play a role.
[0029] Theoretical models and field observations suggest that, local fluid pressures can exceed lithostatic pressure, generating large hydrofractures that are capable of cutting up from a reservoir and through impermeable cap rock. Although only some large fractures cut through many stratigraphic layers, they interact with the entire fracture network by crosscutting smaller features and are capable of transporting fluids over large distances as observed in the Uinta basin, where field observations have identified natural hydrofractures that transported fluids for several kilometers vertically and tens of kilometers horizontally.
Use of Geochemistry in Fluid Flow Studies
[0030] The exhaustive list of considerations included above provides an example of the varied and complex manner in which fractures can influence fluid migration and the numerous dynamic fracture-related processes that can change both geospatially and over time. These considerations depict the difficulty of developing a theoretical model for fracture fluid flow and hydrocarbon extraction from shales. The level of current modeling capabilities, varied geological structure throughout hydrocarbon lithology, and dynamic changes within the fracture network lead to expensive and economically imprudent drilling of many failed, non-productive wells. By placing direct empirical measurement of conservative, in situ, and natural tracers for methane diffusion and fluid flow on the micro-, meso-, and macro-scale in its geostructural framework, the present invention provides a cost effective solution. The present invention develops a regional “sweet spot” model, by first understanding micro-scale fluid flow and meso-scale gas diffusion and flow. Therefore, by determining fracture flow rates, fracture flow direction, and the geometry and properties of the fracture network before horizontal drilling and hydraulic fracturing the present invention improves the success rate of drilled wells.
[0031] The present invention first considers the appropriate geochemical tracers for evaluating micro-scale and macro-scale fluid flow in fractures. Two tools are chosen for analyzing fluid flow in fractures: (1) Noble Gas Geochemistry (NG): He, Ne, and Ar (useful for directly quantifying fluid migration through the complex fracture network on the meso-scale and macro-scale) and ( 2 ) trace element (TE) microchemistry by Cryogenic Laser Ablation Inductively Coupled Plasma Mass Spectrometry (CLA-ICP-MS): transition metals (Mn, Fe, Ti), rare earth elements (La—Lu), and actinides (Th/U) (used to evaluate microchemistry changes (˜5 μm scale) providing a geological record of fluid through fractures).
Noble Gas Geochemistry
[0032] The inert chemical nature of noble gases makes them ideal tracers of fluid origin, fluid diffusion, fluid-rock interaction, and fluid flow mass balance in the Earth's crust. In crustal fluids, including hydrocarbons, noble gases are derived from three main sources including mantle (M), crust (C), and atmosphere (A). In most organic-rich shales, mantle-sourced noble gases do not play a significant role and are therefore excluded for brevity. Crustal (C) and atmospheric noble gases, however, do have significant sources in such organic-rich shales, while each respective reservoir has a unique noble gas elemental and isotopic composition. The changes in the noble gas composition that occur as fluids migrate along fractures and interact with crustal fluids primarily relate to the radiogenic nature of the rock protolith and its geologic history. Uranium (U) and thorium (Th) (both of which are present at relatively high concentrations in most black shales decay to 4 He (alpha-particle: α) (i.e. (235 or 238) U and 232 Th 4 He) simultaneously producing an array of minor nuclear reactions. For this study, an important interaction produces Ne-21 when the alpha particle strikes an O-18 nucleus [ 18 O(α,n)→ 21 Ne]. Other various reactions that produce Ne isotopes (i.e. 24 Mg (n,α)→ 21 Ne and 3 He, 25 Mg (n,α)→ 22 Ne and 3 He, and 23 Na(n,α)→ 20 Ne and 3 He or are not significant in most crustal settings with the exception of fluorine-rich rocks that produce Ne-22. Black shales also contain significant amounts of potassium ( 40 K) which decays to ( 40 Ar) ( 40 K→ 40 Ar) that ultimately ends up in many crustal natural gases. The above interactions lead to significant increases in [ 4 He] (i.e. low radiogenic or crustal 3 He/ 4 He (e.g. 1×10 −8 or 0.01Ra, where Ra: 1.39×10 −6 )), enriched 21 Ne/ 22 Ne (e.g. 0.035-0.050 elevated from the air value of 0.029 by nucleogenic production), and drastically increased 4 He/ 21 Ne (excess) (e.g. 20×10 6 ) as hydrocarbon and groundwater fluids interact with fracture surfaces. Atmospheric noble gases (ANG) are incorporated into crustal fluids (i.e. mainly groundwater) either when water equilibrates with atmospheric gases prior to being recharged into the subsurface (termed air saturated water (ASW) or as sedimentation pore water at the time of sediment deposition. The relevant concentrations of ANG in groundwater are dependent upon temperature equilibrium at the time of recharge and the Henry's Law solubility of each noble gas where the Henry's Law constant increases in the heavier noble gases (i.e. solubility: He<Ne<Ar<Kr<Xe). In comparison to crustal gas interaction, circulating fluids with ASW composition have low [ 4 He] (but higher 3 He/ 4 He (e.g. 1.36×10 −6 or ˜0.985Ra, where Ra: 1.39×10 −6 )), atmospheric 21 Ne/ 22 Ne (e.g. 0.0289), and low solubility controlled 4 He/ 21 Ne (e.g. 85). Noble gas compositions with ASW composition would indicate fluid flow through permeability, highly fractured fracture network. Thus, the amount of ASW gas in a natural gas deposit (e.g. 36 Ar content-ppm) is often a function of the amount of fluid flow or residual pore water. Ballentine et al. (2008) and Gilfillian (2009) have modeled these interactions in a series of papers on the major carbon dioxide rich gases of the western US. It is herein proposed that gas (and rock) samples with dominantly ASW composition may have witnessed major fracture flow that led to extensive hydrocarbon loss. By measuring the noble gas composition in pore fluids and retained in mineral lattices (country rock and vein minerals) the origin and subsurface interaction of hydrocarbons in the subsurface can be constrained, enabling the quantifying of the migration with a fractured network.
[0033] Noble gas (NG) geochemistry has been used to constrain the permeability, effective porosity and the interaction of sedimentary basins with groundwater and to trace basin-wide migration of methane and other hydrocarbons. In addition, NG studies have identified when groundwater flow is dominated by advection through fractures and quantified interaction of fracture network fluids with surrounding rock.
[0034] In shale, the production of 4 He and 21 Ne by radioactive decay of the uranium and thorium series produces an alpha particle that travels 6 to 8 microns and can either embed in a quartz grains as a He atom, or, interact with an 18 O atom within the quartz to produce 21 Ne. The 4 He/ 21 Ne production ratio in quartz is 2.2×10 7 , that is one out of every 22 million alpha decays produces 21 Ne in quartz. These two decay products ( 4 He, 21 Ne) are useful for tracing fluid flow because they interact with quartz crystals differently. 4 He has a small atomic radius that can diffuse through quartz over geologic time scales. Over millions of years, the helium in the pore space (freely available to interact with circulating fluids) and the helium concentration in the quartz crystal reach equilibrium. 21 Ne formed within the quartz grain has a larger atomic radius and has limited diffusion in quartz at room temperature but is only re-released at higher temperature or as the result of quartz breakdown. Thus, fluid flow along fractures in sedimentary basins reduces 4 He concentrations in the quartz (as gas is removed with circulating crustal fluids) while 21 Ne remains trapped in the quartz. Because 1 He and 21 Ne are produced throughout the lifetime of the shale they give an estimate of the total flow of gases since lithification and when measuring spatially within and/or near fractures can provide an estimate of volume of shale that has been degassed. Helium, which is more diffusive than methane, effectively provides a tracer of gas diffusion from the country rock into fractures with fluid mobility.
[0035] This hypothesized behavior of the He and Ne in quartz suggests that in areas with widely spaced and flow accommodating fractures, draining of noble gasses along fractures would result in a gradational decrease in 4 He/ 21 Ne concentrations in rock as the distance to the fracture decreases (i.e. closer to fractures more degassed). In areas that have seen little fluid flow, the He/Ne ratio will approach the anticipated production ratio (e.g. 4 He/ 21 Ne: 2.2×10 7 ) as determined by measuring [U] and [Th]. Conversely, in regions close to very conductive fractures more than 95% of the helium will be lost. By contrast, a much lower 4 He/ 21 Ne ratio can be expected in areas with a high density of conductive fractures as has been observed previously (Cook et al., 1996). Measuring the 4 He and 21 Ne concentrations and constructing a degassing/diffusion profile is useful for identifying areas where extensive fluid flow has occurred. Testing the retained 4 He (i.e. highest diffusion coefficient) in a fractured but relatively impermeable rock provides an estimate of total permeability of the formation. If noble gas ratios, specifically at depth, show an ASW profile without significant interaction with crustal fluids (e.g. 3 He/ 4 He: 0.51.0 Ra, and ASW 21 Ne/ 22 Ne: 0.029), there is a potential for extensive noble gas and hydrocarbon loss from previous fluid flow along fractures throughout geological time. These areas can be avoided when choosing where to drill. By contrast, if noble gas compositions show extensive interaction with crustal fluids and a diffused 4 He/ 21 Ne p rofile (much below production ratio), then we anticipate high fracture network hydraulic conductivity (K FN ) without prior loss of crustal noble gases and hydrocarbons is anticipated. These locations would define sweet spots because of their high K FN will enable fluid extraction along the naturally occurring fracture networks. Alternatively, if an area has a 4 He/ 21 Ne approaching production ratios it would imply true “tight gas” country rock with a poor fracture network. While these potential plays would still retain hydrocarbons, economically viable extraction along natural fracture networks is unlikely. These areas would require more costly horizontal drilling and hydraulic fracturing, but still lead to less production making less than optimal hydrocarbon plays.
Vein Trace Element Microchemistry by Cryogenic LA-ICP-MS
[0036] Past research has shown that hydrocarbons, groundwater, and radiogenically produced gases interact in the subsurface with circulating fluids imprinting their chemical signature on the immobile fraction. Indeed, the movement of water in the subsurface has profound implications for collection, migration, and entrapment of natural gas and oil. Helium, methane, and water all migrate along the same fracture pathways, while 4 He/ 21 Ne and 4 He record the relative amount of fluid degassing and the pathways along which water and mobilized hydrocarbon fluids travel. However, noble gas methodologies alone do not preserve a record of the volume of water flux, timing, or cycles of fluid migration in black shales.
[0037] Conversely, vein filling minerals (such as calcite) incorporate the chemical composition of pore fluids during mineralization providing a geochemical archive of pore fluid chemistry throughout various flow events during vein formation. As a result, vein minerals record the micro-scale interactions of fluids with fracture surfaces. Trace element concentrations in calcite veins, specifically rare earth elements (REEs), oxyanion forming trace metals (OFTM) (e.g. Mn, Fe, As), and actinides (Th and U) may be used to estimate the volume of fluid migration, number of pulses of fluid migration, the source chemistry with which fluids interact, changes in fluid chemistry (e.g. pH, redox potential) and the time of vein filling.
[0038] This suite of TEs (i.e. oxyanions forming transition metals, REEs, and actinides) is selected in order to evaluate the interaction of migrating fluids and fractured country rock during fluid migration because they have a high degree of interaction with fracture surfaces and a preference to precipitate from water and incorporate into vein forming minerals in a predictable pattern dependent upon each of their individual chemical affinities. These characteristics result in their ability to accurately record relevant changes in pH, E H (oxygen fugacity), and saturation conditions (i.e. relative volume of water flux). For example, Mn and As oxyanions complexes are conservative and highly mobile at a neutral to basic pH across a range of E H conditions, while REEs are only mobile in acidic and highly saline conditions and travel primarily with dissolved organic carbon (DOC) all of which lead to a measurable fraction of these elements in vein calcites. U and Th in country rock are fractionated when interacting with crustal fluids because U has the ability to complex with DOC or form oxyanions, leading to low relative Th/U in fluids transported along fractures as compared to fluids directly interacting with country rock. Comparatively immobile trace elements such as REEs and Th will increase during low fluid transport (i.e. greater interaction with country rock) and decrease during periods of high rates of fluid transport as has been observed for some transition metals including Fe and Mn.
[0039] Because vein mineralization occurs slowly over geological time, exceedingly small analytical resolution is needed in order to evaluate spatial changes in chemical composition within vein minerals. The advent of high resolution LA-ICP-MS enables the in situ analysis of these selected trace elements within individual veins to a resolution of several dozen microns (˜20 μm). This capability allows microchemical spatial determination of calcite vein chemistry, a proxy for pore fluid evolution through fractures.
[0040] However, the current state of LA-ICP-MS capabilities poses two potential problems for the analysis of vein mineralization, which include significantly lower analytical sensitivity as compared to solution based-ICP-MS and poor laser coupling with organic-rich country rock and vein minerals.
[0041] While some trace elements are present at easily detectable concentration in vein minerals (Mn, Fe, Zn, La, Ce), these analytes can only be reliably measured at a resolution of ˜20 μm (20 μm spot size). Although this spatial resolution is markedly better than in solution analysis, optical mineralogical observations show precipitations fronts on the scale of a few microns (˜10 μm). A current laser ablation system can ablate to a spot size approaching 2 microns, but sensitivity is decreased at a smaller spot size. Additionally, even if smaller spot size reaches sufficient spatial resolution, it still does not permit robust ablation of organic-rich materials. To overcome this analytical hurdle, a high sensitivity, fast washout cryogenic laser ablation system (GMA 4200Volante CryoCell) is used. This cryogenic laser ablation system cryogenically freezes the organic material enabling robust and reproducible analysis of organic-rich samples. Additionally, the GMA Volante laser ablation cell, when combined with cryogenic capability, improves analytical sensitivity ˜10× enabling analysis of REEs and actinides (Th/U) and providing sufficient spatial resolution to monitor the record of fluid flow fluctuations throughout geological time.
[0042] Therefore, the claimed combination of trace element microanalysis and noble gas techniques provides a framework to understand the characteristics, cycles, and timing of fluid flow and the potential for hydrocarbon fluid extraction. These claimed methodologies, enable the development of basin scale maps depicting “sweet spots” (hydrocarbon-bearing and conductive along natural fracture network), “dead spots” (and highly fractured and extensively diffused without a history of crustal interaction), “potential spots” (where “tight gas” extraction will be expensive despite the presence of hydrocarbons), and ground truthing well selection procedures within hydrocarbon producing black shales.
[0043] Although several studies have examined the chemistry of fractured rocks in the Appalachian basin by using fluid inclusions in veins, little work has been done on the partially mineralized fractures that likely accommodate fluid flow. In addition, past research has focused on either the mechanical properties of individual fractures, or modeling flow through fracture networks based on fracture orientations. The present invention takes a uniquely integrated approach, using a combination of fracture network analysis and applying geochemical tools to evaluate the flow of hydrocarbons through the fracture network within hydrocarbon producing black shales.
[0044] The present invention addresses the role of natural fractures on fluid distribution and flow in shale in four ways: (1) mapping the physical characteristics of fracture sets such as the 3-D fracture network geometry, and interpreting fracture history based on cross cutting relationships (geostructural analysis); (2) analyzing the microchemistry of individual types of open and vein-filled fractures to determine fracture interaction with fluids (cryogenic LA-ICPMS (CLA-ICP-MS) TE geochemistry) ; (3) measuring the percent change in the bulk permeability of the shale due to fracturing (NG and (CLA-ICP-MS) TE geochemistry); and (4) assessing the current basin scale variations in the NG chemistry to determine system scale gas diffusional loss. By looking at what controls fluid flow at different scales, the present invention enables the identifying of the contributions of different variables, whether regional-scale or microscale, and the understanding of the interplay between them. This is of fundamental importance in understanding geologic fluid flow through a fractured medium and something that previous studies have failed to capture. In addition, the present invention comprises a suite of methods that can accurately assess modern day fluid flow through fractured rock providing near real-time in situ measures of fluid migration.
Microscale Studies
[0045] In order to understand the effect of fracture systems on fluid flow, the role of individual fractures in the process must first be understood. Geostructural analysis evaluates the role of individual fracture characteristics (i.e. aperture, size, roughness, mineralization, and chemical characteristics) on fluid flow. Preliminary data finds un-mineralized, partially mineralized, and completely healed fractures in some shale. When fluids migrating along fractures become supersaturated with respect to dissolved elemental concentrations they grow crystals into open fractures, which incorporate and record elemental composition of the fluids. By examining elemental crystal microchemistry of minerals across the aperture of a fracture fluid composition changes over time can be evaluated to determine the fracture characteristics that best accommodate fluid flow and maximize extraction efficiency.
[0046] Preliminary optical microscopy shows euhedral calcite crystals, which indicate growth into open and fluid filled fractures. Nascent crystal growth proceeds from fracture walls progressively towards the fracture opening until the fracture heals or fluid flow stops. Preliminary CLA-ICP-MS analyses of vein chemistry show an exciting pattern of Mn and REE concentrations in calcite crystals. Microsampling of an individual vein (˜4.5 mm thick) at 10-micron resolution shows cyclic variations in REE concentrations with three peaks per cross section showing a 6-8 times increase in
[0047] REE levels. The average wavelength of these cycles is approximately 1.3 mm and suggests the occurrence of at least three distinct fluid flow events during vein formation. CLA-ICP-MS mapping (multiple stitched lines at 5 μm resolution (spot size) to produce a map ˜6 mm×10 mm) on partially mineralized fractures and healed fractures (veins) is conducted to examine the spatial changes in trace element chemistry across individual fractures as a proxy for cycles of fluid flow and mineralization. CLA-ICP-MS provides accurate spatial micro-sampling at geochemically relevant intervals in organic-rich samples with sufficient analytical sensitivity and specificity to accurately determine actinides and REEs in calcite veins OFTM (e.g. Mn, As), REEs, and actinides (Th/U) in vein minerals are analyzed because they are ideal tracers for the evolution of fluid chemistry and the interaction of migration fluids with fracture surfaces within country rock.
[0048] In addition to studying the cycles of fluid flow, noble gas chemistry of vein fluid inclusions is analyzed to provide a snapshot of basin chemistry at the time of vein formation. Noble gas composition from these fluid inclusions is compared with trace element and noble gas chemistry of vein minerals to evaluate gas diffusion as the system changes. The combination of these tracers can then be used to develop a gas diffusion/migration model for fluids on the microscale.
Mesoscale Studies
[0049] After determining the fluid flow characteristics of individual fractures (microscale), the findings are integrated to determine the fluid flow properties of a fracture system as a whole to determine the most efficient fluid flow pathways. To understand the role of the mesoscale factors (stress field, fracture geometry) on fluid flow, the history of fracture sets in the target shale and fracture fluid flow relationships are determined. Two techniques are combined: detailed three-dimensional, sub-meter to km-scale mapping of fractures and sampling for NG and vein TE signatures to correlate fracture patterns with fluid flow.
[0050] In one embodiment of the present invention, geostructural mapping is conducted in quarries that cut through the target shale into the underlying limestone. Quarrying leaves a terrace at the base of the shale providing optimal opportunity to observe 3-D exposure. Corners of a quarry have been found to allow examination of the intersecting walls and the quarry floor, providing a detailed picture of the 3-D fracture network. The quarry opening also allows opposite walls to be compared at ˜1 km distance and large scale structures (faults, folds) to be accurately mapped and correlated with variations in fracture patterns. Detailed mapping is done using a meter-square grid with 10-cm subdivisions, while mapping at the 10-1000 m scale is carried out with GPS-based laser rangefinder techniques that allow positional accuracy of <10 cm at a distance of 100 m.
[0051] Preliminary research has shown multiple fracture sets of different types and orientations in the target shale formations. In addition to joints, conjugate sets of transverse shear fractures, extensional joints and low angle fractures with reverse shear are shown. This allows observation of calcite veins and partially mineralized fractures with calcite bridges that record several generations of fluid flow as described earlier.
[0052] When fracture network geometry from field studies is combined with NG isotopic data, it can determine which fracture sets accommodate fluid flow and identify sweet spots, as described earlier from work on groundwater systems in fractured rock. Samples for NG-MS will be collected from different sets of fractures and host rocks in a variety of locations using a 1-inch core drill. Quantitative fluid flow data is compared with fracture patterns to constrain fracture network effects, and group fractures so that the properties of individual fractures can be used to further understand the flow of hydrocarbons in the target shale.
Regional Variations
[0053] Quarries from different parts of the target outcrop belt are studied in this way so that the data can be compared to understand regional variations. In one embodiment of the present invention, drill-cores will be available from a few select test wells in the area, so that variations between the shale at-depth and newly exposed shale at the surface in quarries can be tracked.
[0054] Basin wide changes due to fracturing of the target shale are evaluated by combining [U] and [Th] data with NG-MS analyses. By measuring shale [U] and [Th], the anticipated 4 He/2 21 Ne production ratio is calculated in comparison to measured 4 He/ 21 Ne. The mechanically calculated permeability of the shale is then used to determine the partitioning of He between pore space and crystal, which values are compared with the observations to gauge the effect of different degrees of fracturing in different areas. Assuming that the 21 Ne remains in the mineral phases, the ratio of 4 He/ 21 Ne relative to production will provide evidence for the amount (volume) of fracturing and hydrocarbon loss in the shale.
Summary
[0055] It can thus clearly be seen that the predictive methodology for directly evaluating fluid flow through natural and stimulated fractures in situ by integrating noble gas geochemistry, trace element geochemistry, fracture analysis, and regional structural geology is a significant improvement over the extant shale hydrocarbon extraction methods. Not only is well-selection success rate improved and the use of geologic features maximized, but hydrocarbon extraction is improved and recovery costs are reduced dramatically
[0056] What has been described above includes examples of one or more embodiments. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the aforementioned embodiments, but one of ordinary skill in the art may recognize that many further combinations and permutations of various embodiments are possible. Accordingly, the described embodiments are intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim. | American energy costs steadily increase leading to increased unconventional energy use. However, scientific barriers prevent widespread and economic development of these resources. In gas shale plays, resource utilization is limited by the understanding of how hydrocarbons and other fluids migrate in fractured rock. This limits industry's ability to extract hydrocarbons with enhanced recovery methods; prevents exploration in areas where hydrocarbons do not collect in traditional traps; and could unfortunately lead to dangerous environmental consequences such as contaminated groundwater. To address these concerns, the present invention integrates geochemical and geostructural techniques in a novel method for evaluating and optimizing the placement and drilling strategies of extraction wells in hydrocarbon rich black shales. By correctly choosing hydrocarbon “sweet spots” companies can reduce the number of unprofitable wells, choose directional drilling and completion strategies to accurately reflect the subsurface, and better select prime small- and full-field reservoirs. | 4 |
BACKGROUND OF THE INVENTION
The invention relates to a self-supporting composite plate, especially for double floors, with a pan-shaped outside wrapping to hold filler material which is flowable or feedable and hardenable, with high compression resistance when hardened, e.g. anhydrite, concrete or the like.
A self-supporting composite plate of this type is known from German Patent No. 2,004,101. The pan-shaped wrapping of this composite plate has a practically planar bottom and its total unobstructed section is filled with anhydrite or the like, so that the composite plate is correspondingly heavy. In many cases, however, a lightweight plate is preferred, but without loss of the numerous advantages of this composite plate, e.g. the great fire-resistance, carrying capacity, impact sound insulation and so forth.
Double floor plates are also already known from German Patent Nos. 3,103,632 and 2,930,426, which have numerous burl-like projections on their bottoms, which however are totally supported on a foundation, and a plurality of supports are thus formed. These double floor plates may be lighter than the aforementioned composite plates, but they are not self-supporting, i.e. cannot be supported exclusively at their corners on footrests, because the wrapping required for this is not present.
U.S. Pat. No. 4,411,121 discloses a double floor plate of steel, which includes a planar cover plate, welded onto the apexes of a plurality of cupola-shaped projections as well as onto the surrounding, upward-curved edges of a bottom part. This double floor plate is also relatively heavy, but its main drawback is that, if a fire breaks out in the hollow space of the double floor, there is practically unhindered heat transmission in the space found over it with all of the inherent disadvantageous results, because of the metal connection of the bottom with the top of the plate.
SUMMARY OF THE INVENTION
The object of the invention is to construct a self-supporting composite plate of improved structure, so that it is remarkably lightweight and its advantageous properties described above are nonetheless retained.
In the present invention, the pan-shaped wrapper is provided with a plurality of burl-like projecting blocks, containing filler material, which are connected with each other by a base element of high tensile strength. If one assumes the same structural height of the known composite plate as the composite plate according to the invention, then a remarkably lower quantity of filler is incorporated by the burl-like projecting blocks on the bottom of the pan-shaped wrapper of the invention than by the corresponding bottom unobstructed sectional area of the known pan-shaped wrapper with a practically planar bottom. The weight reduction thus produced with the finished composite plate in comparison with the state of the art is approximately 40%. From a static point of view, the smaller quantity of filler in the bottom sectional area of the composite plate (beneath the middle plate plane) is irrelevant, since only tensile stresses occur in this area henceforth with loading of the composite plate, and very low tensile strength and very low elasticity module are required. The high carrying capacity of the composite plate according to the present invention is assured in that a base element of high tensile strength is mounted on the burl-like projecting blocks which are projecting downwardly and which absorb the traction or tension on the bottom.
Because of the arrangement of such a base element, it is also possible to use relatively thin material for the pan-shaped wrapper, which favorably effects its manufacturing cost. A sufficient quantity of filler for the impact sound insulation is also in the composite plate according to the present invention. The relatively high fire-resistance of the composite plate is assured by use of a sufficiently thick filler layer for this purpose, over the total plate section between the pan-shaped wrapper and the plate surface. Any desired floor covering of course can be mounted on the plate. The burl-like projecting blocks on the bottom of the pan-shaped wrapper are preferably of uniform configuration and are arranged in a uniform arrangement and manufactured most appropriately by deep-drawing, using sheet steel for the pan-shaped wrapper. The base element of higher tensile strength can be welded, glued, riveted or even screwed onto the burl-like projecting blocks.
As an illustrative example, the base element can consist simply of a thin sheet metal plate. For further weight reduction of the composite plate, the base element can be perforated.
The flex-resistance of the composite plate is improved if the base element is provided with reinforcement in the form of stiffening corrugations or the like. According to another configuration of the invention, the base element may also be configured as a grid, e.g. a structural steel grid.
The burl-like projecting blocks can be approximately half the total height of the pan-shaped wrapper and thus can be below the middle plane of the composite plate. Also, the burl-like projecting blocks can be configured as truncated cones, with smaller diameters to the outside. Truncated cones as burl-like projecting blocks are preferred for simplified removal of the finished pan-shaped wrapper from the deep-drawing tool.
According to still another configuration of the invention, if the burl-like projecting blocks, because they taper somewhat, arch slightly upwardly at the middle of the pan-shaped wrapper, so that following subsequent introduction of the filler material, the bottom and top of the composite plate are substantially parallel to each other, the slight flexing of the pan-shaped wrapper caused by the weight of the filler material is advantageously compensated.
In a composite plate of which the pan-shaped wrapper has openings with inward pressed edges for anchoring in the filler material, it is appropriate for reasons of production that the bottoms of the burl-like projecting blocks incorporate these openings.
According to still another configuration of the invention, when the openings in the bottoms of the burl-like projecting blocks are closed from the outside by the base element, the filler material cannot penetrate through these openings insofar as it is still found in flowable or feedable state. The plugging materials introduced through the openings until this time for the same purpose are thus advantageously replaced by the base element.
The point welding process is simplified if the burl-like projecting blocks are provided with weld projections on their bottoms for alignment of the base element.
BRIEF DESCRIPTION OF THE DRAWING
The present invention is explained hereinafter relative to the drawings of exemplary embodiments.
FIG. 1 is a top plan view of a pan-shaped wrapper for a self-supporting composite plate according to the present invention;
FIG. 2 is a partial sectional view taken substantially along line II--II of FIG. 1, with a sheet metal plate as the base element before its connection with the pan-shaped wrapper by point welding, the wrapper being filled with filler material;
FIG. 3 is an enlarged partial side elevational view in section of a finished self-supporting composite plate, which includes the pan-shaped wrapper of FIGS. 1 and 2 as well as a welded-on base element; and
FIG. 4 is a partial side elevational view in section similar to that of FIG. 3, showing a finished self-supporting composite plate with different embodiments of the pan-shaped wrapper and the base element.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The self-supporting composite plates 10 and 10A shown as exemplary embodiments in FIGS. 3 and 4, respectively, form base plates for double floors. Such base plates are laid out with their edges tightly joined and are supported at their corners on footrests or the like, which in turn are mounted in the foundation of the building.
Composite plate 10 includes a pan-shaped outside wrapper 11, which in a preferred embodiment is formed of sheet steel with a surface protection, e.g., a zinc coating. The pan-shaped wrapper 11 has a plurality of uniformly arranged burl-like projecting blocks 12 on its bottom, which preferably are formed together with the upwardly projecting, surrounding side walls 13 thereof in a deep-drawing process. These burl-like projecting blocks 12 are in the form of truncated cones which taper slightly inwardly and downwardly. The height of projecting blocks 12 corresponds approximately to half the height of wrapper 11, and the height of the burl-like projecting blocks 12 at the middle of the pan-shaped wrapper 11 can be tapered progressively so that the bottoms 14 of projecting blocks 12 are curved slightly upwardly toward the middle of the wrapper. This adds the advantage that, during the hereinafter described introduction of filler material into the pan-shaped wrapper, as a result of the weight of the filler material, pan-shaped wrapper 11 is deformed downwardly in the middle to such an extent that the bottom and top of the finished composite plate 10 run substantially parallel to each other. With, e.g., 600 mm edge length of finished composite plate 10, the burl-like projecting blocks 12 could have a smallest diameter of 20 mm and could be arranged with a mutual spacing of 40 mm, measured from midpoint to midpoint of the projecting blocks.
On the smooth bottom 14 of each burl-like projecting block 12, there is point-welded a thin sheet metal plate serving as base element 15, which can be provided with openings 16 between projecting blocks 12 and opposite the hollow spaces, to further save weight, as is shown in FIG. 4. FIG. 2 shows that, on the outside in the middle of the projecting block bottoms 14 are arranged weld projections 17, which simplify the alignment of base element 15 for use of a suitable point welding machine. When finished composite plate 10 is loaded, the base element 15 serves to absorb tensile stresses and preferably is provided with a surface protection, e.g., a zinc coating, similar to pan-shaped wrapper 11.
For completion of the self-supporting composite plate 10, a flowable or feedable and hardenable filler material 18, preferably anhydrite, is introduced into pan-shaped wrapper 11 which is open at the top. After it passes through a vibration station, excess filler material 18 is stripped or peeled off, in order to attain a smooth upper surface 19, as shown in FIGS. 3 and 4. Surface 10 can be abraded following subsequent hardening of filler material 18, so that it is henceforth planar. A flooring 20 is then mounted on surface 19, e.g., a carpet, a plastic plate or the like, adhesively mounted.
The self-supporting composite plate 10A shown partially in FIG. 4 essentially corresponds to that of FIG. 3 and the same parts thus have the same identification numbers. As opposed to the embodiment of FIG. 3, however, pan-shaped wrapper 11 on its surrounding side walls 13 as well as on the bottoms 14 of its burl-like projecting blocks 12 is provided with openings 21 with inwardly-drawn edges, which serve to combine or interlock pan-shaped wrapper 11 with filler material 18. The filler material which is forced into the openings 21, following its hardening, forms substantially conical anchoring members. The corresponding individual features are disclosed in detail in German Patent No. 2,004,202.
The thin sheet steel fastened by point welding onto the bottoms 14 of projecting blocks 12, and serving as base element 15', serves not only to absorb traction stresses with loading of composite plate 10A, but also, during the filling process, serves to prevent discharge of filler material 18 from openings 21 in the bottoms 14 of the projecting blocks 12. Openings 21 in the side walls 13 of pan-shaped wrapper 11 for the same reason are closed on the outside with an adhesive strip (not shown) or the like. As previously described, the sheet metal plate serving as base element 15' in the embodiment of FIG. 4 has openings 16 between the projecting blocks 12 for weight reduction.
Within the scope of the present invention the burl-like projecting blocks 12 in pan-shaped wrapper 11 could also be configured as cylinders or polygons. Although zinc-coated sheet steel is preferred for the pan-shaped wrapper 11 and base element 15 and 15', these structural parts could be formed of other suitable materials. | A self-supporting composite plate for double floors or the like, comprising a pan-shaped wrapper for receiving therein a flowable and hardenable filler material of high compression resistance when in a hardened state, such as anhydrite or concrete. The pan-shaped wrapper comprises a plurality of downwardly extending burl-like projecting blocks containing the filler material. A base element of high tensile strength is connected to the projecting blocks. | 4 |
BACKGROUND OF THE INVENTION
The invention relates to an apparatus for electronic engine control with a performance check for the final ignition stage and comprising an electrical control circuit for controlling the final ignition stage and/or fuel injection as a function of engine parameters such as engine temperature, engine speed, and the like.
Electronic engine control systems are known which comprise a processor which controls the engine operation taking into account various engine parameters. In particular, the optimal fuel injection quantity and the optimal ignition timing are determined as a function of engine speed, engine temperature, position of the accelerator pedal, and consideration of the characteristic diagrams of the specific engine. In the known engine controls, the engine parameters listed above are determined by suitable sensors. The engine speed can be determined, e.g., at the camshaft, the engine temperature can be determined by a thermal element, and the position of the accelerator pedal can be determined by a distance sensor or indirectly by an angle pickup which determines the position, of the throttle valve. Such an engine control is known, e.g., from DE-OS 35 41 731.
In motor vehicles whose exhaust system is equipped with a catalyst, unburned fuel can reach the catalyst in a faulty final ignition stage and destroy it while releasing extraordinarily high heat energy. There is a danger not only of the catalyst being destroyed, but even that the vehicle may catch on fire.
SUMMARY OF THE INVENTION
The object of the invention is an apparatus for electronic engine control in which the a failure of the final ignition stage is detected and a corresponding error flag is prepared. The object of the invention is achieved by arranging an ignition voltage detection sensor at at least one ignition cable leading away from the ignition coil and communicating the sensor output signal to CPU. The error flag can serve, on one hand, to activate an error display. However, it is preferable to use the error detection for switching off the fuel injection, wherein the fuel injection remains switched off until an error is no longer detected and a switching on of the fuel supply is permissible again while taking into account the respective engine operating state.
Since a switching-off of the fuel supply is generally not required with a single ignition failure, a further development of the invention provides that the error flag is fed to a counter as a counting pulse, and that the fuel injection is switched off when a predetermined reference counter state is reached. The reference counter state can be adapted to the exhaust system or to the construction type of the catalyst and engine, so that the fuel injection is switched off, e.g., only after five successively determined ignition failures. When the presence of the correct ignition voltage at the ignition cable is determined after switching off the fuel injection, the counter is reset and the fuel injection is switched on again. However, this is preferably effected only under the condition that a thrust cut-off caused by letting up on the accelerator pedal has been determined immediately beforehand. This condition has the advantage that no sudden switching on of the fuel injection and accordingly no unexpected acceleration is triggered. When turning on the fuel injection in the thrust cut-off operating state, the fuel injection is released, but an injection of fuel is prevented for the time being as long as the thrust cut-off operating state is maintained. Normal fuel injection is then effected only after renewed actuation of the accelerator pedal.
An inductive sensor is preferably arranged in the area of an ignition cable leading to a spark plug, the sensor output signal of the inductive sensor being converted into a rectangular pulse by a signal converter. This rectangular pulse can be digitally processed directly in the processor.
In ignition systems with a plurality of final ignition stages, as used in six- or eight-cylinder engines, a sensor and a counter are assigned to every final ignition stage in order to carry out a separate performance check for every final ignition stage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a block wiring diagram basic construction of an apparatus for engine control engine control;
FIG. 2 shows a wiring diagram of the engine control with a final ignition stage; and
FIG. 3 shows a function diagram for the engine control shown in FIGS. 1 and 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The block wiring diagram shown in FIG. 1 shows the basic construction of an apparatus for engine control with performance check for the final ignition stage. A sensor 1, which is assigned to an ignition cable 2, sends a sensor output signal SO at its output side when an ignition voltage occurs. The sensor output signal SO is converted into a rectangular signal SI in a signal converter 3 and is fed to the input of an engine control 4. The engine control in turn controls the injection system 5 and the ignition 6 of an internal combustion engine. The sensor 1 can likewise be arranged on the cable 30 between the ignition coil 11 and distributor 9. If the position of the distributor rotor arm 9 or crankshaft is known, the occurrence of an ignition voltage can be determined for every spark plug 8 with a single sensor in a manner directed specifically to the cylinder. If a determination relating to the specific cylinder is not important, the crankshaft position or position of the distributor rotor arm 9 need not be known. In this case, it is sufficient to observe the type of sensor signal SO.
Various parameters, such as rate of rotation n, engine temperature T, throttle valve angle, which characterize the respective operating state of the engine, are assigned to the engine control 4 which controls the engine while taking them into account. Characteristic lines and/or characteristic diagrams relating to the specific engine which are taken into account for the control tasks of the engine control memory are stored in the engine control. The control of engine operation with the aid of characteristic lines and characteristic diagrams is known per se and is not the subject matter of the present invention; therefore, a more involved description of the implementation of the engine control is not discussed here.
A more detailed block wiring diagram with ignition devices is indicated in FIG. 2.
An induction sensor 1 encloses the ignition cable 2, which leads from an output of an ignition distributor 7 to a spark plug 8 or the cable 30. The ignition distributor 7 has a total of six outputs A1 to A6 which lead to a spark plug. A distributor rotor arm 9, connects the outputs A1 to A6 consecutively with the output 10 of an ignition coil 11 which is activated by a final ignition stage 12.
When an ignition voltage occurs at the ignition cable 2 or cable 30, the sensor 1 sends a sensor output signal SO to a filter 13 whose output is connected with the input of a rectifier 14. The output signal of the rectifier 14 is fed to the positive input of a differential amplifier 15 whose negative input is connected to a threshold value voltage Us. If the output signal of the rectifier 14 exceeds the voltage value of the threshold voltage Us, a positive voltage occurs at the output of the differential amplifier 15 until the output signal of the rectifier 14 falls below the value of the threshold value voltage Us again. Accordingly, a rectangular signal SI occurs at the output of the differential amplifier 15 when a sensor output signal SO occurs. The filter 13, the rectifier 14 and the differential amplifier 15 together form the signal converter 3, as is shown in FIG. 1.
The rectangular signal SI is fed to an input of a processor CPU which checks whether or not a rectangular signal SI also arrives via the final ignition stage 12 when an ignition voltage is triggered. Since a sensor 1 is arranged only at the ignition distributor output A2 in the present embodiment example, this check is only carried out when the distributor rotor arm 9 is located in the position shown in the drawing.
If the processor CPU determines during a computercontrolled engine control that the rectangular signal SI is not present at the required point in time, a counter Z which is connected to the processor CPU is increased by 1 with respect to its counter state. The current counter state is stored in a memory RAM connected with the counter Z and with the processor CPU. The memory RAM is battery-buffered, i.e. a battery B also protects the contents of the memory when the supply voltage of the engine control fails or is switched off.
Further, a read only memory 16 is connected to the processor CPU, in which a reference counter state which is constantly compared for agreement with the current counter state in the processor is stored. As soon as agreement is determined between the reference counter state and the current counter state, the processor sends an error flag to the battery-buffered memory 17. The fuel injection is switched off simultaneously with the error flag. This is effected in that the final injection stage 18, which is controlled by the processor CPU, is switched off, so that no more fuel K is injected into the combustion chamber of the engine by means of the injection nozzle 19 connected subsequently. As soon as the engine control again determines an error-free functioning of the ignition system, the final injection stage 18 can be reactivated, wherein this should be effected on condition that a release or activation of the final injection stage 18 may be effected after an error flag only in the "thrust cut-off" operating state.
The manner of operation of the control shown in FIG. 2 is explained in more detail with reference to the function diagram shown in FIG. 3.
The processor executes a constantly repeating routine in the performance check which begins by first checking whether or not a sensor output signal SO is present. The sensor output signal is absent when there is a disturbance in the final ignition stage 12 or the ignition devices connected subsequent to the latter, which results in an incrementing of the counter Z. The current counter state is then compared with the permanently stored, predetermined reference counter state. If the comparison is negative, the next cycle of the checking routine begins and the counter is possibly incremented again until the counter state is currently the same as the reference counter state. Since the reference counter state represents the maximum allowable error number, a switching-off of the injection is now effected, wherein an error light can be activated simultaneously. Moreover, a marker, which is usually designated as a flag, acts in the battery-buffered memory 17.
The checking routine is continued and the injection remains switched off until it is determined at the beginning of the checking cycle that a sensor output signal SO is present. Now the contents of the memory are first checked as to whether or not a flag is set. If so, the injection is turned on again and the flag is canceled, but only when the "thrust cut-off" operating state is determined, so that no unexpected sudden acceleration occurs for the driver.
If it is determined in a cycle of the checking routine that a sensor output signal is present and no flag is set, the counter 17 is reset or set to zero, respectively.
It is possible to have the checking routine not run or be ineffective under certain conditions, e.g., when a predetermined minimum engine temperature has not yet been reached. It can also be provided that no checking routine is carried out during the engine starting phase. An interruption of the checking routine can be provided during the thrust cut-off and/or during an acceleration enrichment, depending on the requirements.
While the invention has been illustrated and described as embodied in an apparatus for electronic engine control with performance check for the final ignition stage, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | A method of electronic engine control for a motor vehicle includes sensing an ignition voltage of a final ignition stage, effecting a performance check of the final ignition stage in response to a control signal generated in response to sensing the ignition voltage of a final ignition stage, and providing an error flag if the control signal deviates from a predetermined control signal. An apparatus for performing the foregoing method comprises an electric control circuit that includes a sensor for detecting the ignition voltage, and control means that effects a performance check in response to a sensor output signal and emits the error flag in response to an error control signal. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the detection and evaluation of the extent of degradation or spoilage of finfish tissue caused by bacteria such as pseudomonas putrefaciens, as an indication of the degree of quality of the fish.
The bacterial degradation of fish begins when a fish dies. Bacterial spoilage initially affects the texture and taste of fish and, with time, bacterial growth progresses to the extent that the fish is no longer fit for consumption.
The flesh of living fish is usually free of bacteria, but the normal barriers that protect fish muscle and tissue from invasion from bacteria begin to break down when the fish dies. Thus, if the fish is not fresh, spoilage progresses rapidly to produce a number of metabolic reaction products and odors that vary depending on temperature and age.
From a commercial standpoint it is important for purchasers of large volumes of fish, such as wholesalers and retailers, to be assured of the freshness and quality of finfish being purchased from fishing boats or fleets in relation to the price being asked.
2. Description of the State of the Art
Traditional methods for evaluating the freshness or degree of spoilage of fish include sensory evaluation (appearance, feel and smell), trimethylamine determination and bacterial population determination (total plate counts).
These methods are of only limited use because they are subjective, debatable, require highly trained or skilled personnel and/or specialized equipment, or are too expensive or time consuming for the routine analysis of large numbers of fish. It is highly desirable to be able to evaluate fish quality in-situ, i.e., directly at the retail outlet, and to be able to make an objective evaluation within minutes. The retail outlet is the place where there will be a high degree of spoilage, and where color will most frequently be detected.
SUMMARY OF THE INVENTION
The present invention involves a novel colorimetric method for rapidly evaluating the degree of bacterial degradation, if any, (spoilage) of finfish, such as codfish, catfish and winter flounder, for example, by mixing the fish flesh with a bacterial nutrient broth, and reacting the extract with a water-soluble chromogen such as an ionized tetrazolium dye salt which undergoes a reduction reaction with the fish bacteria to produce a water-insoluble formazan dye or colored reaction product. Next a surface active agent is added, to help solubilize the formed formazan dye, to produce lysis and stop the reaction, and an aliphatic alcohol solvent is added to dissolve the formed formazan dye or colored reaction product, and prevent further breakdown and darkening with time. The dissolved reaction product has a color which is intensified depending upon the bacterial population of the fish sample and which can be evaluated colorimetrically by visual comparison with a standard color chart indicative of low, medium and high bacterial populations, which I refer to under the trademark FishCHECK Color Chart.
THE DRAWINGS
FIGS. 1 to 5 are comparative graphs illustrating the relationship between storage time, aerobic plate count, Pseudomonas putrefaciens count, trimethylamine count and sensory score, respectively, and the % intensity of color developed in the sample broth solutions produced from codfish according to the novel method of the present invention, as measured against the colors of a conventional Pantone® Professional Color System intensity chart such as Pantone® Color Specifier 747XR;
FIGS. 6 to 9 are comparative graphs, corresponding to those of FIGS. 1 to 3 and 5, and pertaining to sample broth solutions produced from catfish according to the novel method of the present invention, and
FIGS. 10 to 14 are comparative graphs corresponding to those of FIGS. 1 to 5 and pertaining to sample broth solutions produced from winter flounder according to the present invention.
DETAILED DESCRIPTION
The novel method of the present invention is one which can be carried out quickly by any lay person, with minimum training, and with portable supplies which can be carried on one's person. The method can be carried out in-situ in any environment, such as on a fishing boat, without interference from the odor of the environment. Also, the test results are objective and visually demonstrated by a color comparison which is clear to any lay person without the need for special training or evaluation equipment. In the case of dark-flesh finfish, such as tuna fish, additional reactants such an oxidizing or bleaching agent, preferably hydrogen peroxide, and a defoamer are added to bleach the muscle pigments and lighten the color of the solution so that any color that appears during the assay is due to the reduction of the tetrazolium dye.
The novel, simplified colorimetric test process of the present invention is based upon the discovery that triphenyl tetrazolium dye salts are colorless, ionized, water soluble and capable of passing through the cell wall into a bacterial cell while undergoing a reduction reaction to form a non-ionic, water-insoluble, red-colored triphenyl tetrazolium formazan compound which is deposited within the bacterial cells. The intensity of the formed color is proportional to the concentration of the bacteria present, necessary to produce the reduction reaction, and therefore the visible color intensity provides a measure of the bacteria concentration which, in turn, provides an indication of the quality of the fish being tested.
The present process is conducted on finfish fillets which are believed to be fresh and/or which have been kept on ice. A predetermined weight of a fish fillet, such as 25 gms, is kneaded with a predetermined volume of a liquid growth medium, such as 25 ml, (1:1 ratio) for 2 to 5 minutes at room temperature, e.g., 23° to 25° C., shaking vigorously, and then a predetermined volume of the liquid filtrate, such as 5 ml, is mixed with a small amount, such as 1 ml, of the colorless triphenyl tetrazolium dye salt indicator reagent and allowed to incubate for 10 to 20 minutes at room temperature, e.g., 15°-25° C., shaking vigorously every 5 minutes. The following reaction takes place with the use of 2,3,5-triphenyl tetrazolium chloride as the indicator reagent: ##STR1## This reduction reaction is enabled by the functioning electron transport system of the viable bacterial flora on the fish and proceeds in proportion to the quantity of the enabling bacteria present. The greater the concentration of the red-colored 2,3,5-triphenyl tetrazolium formazan formed in the bacterial cells, the greater the intensity of the color of the formazan solution extracted from the sample.
Additional essential process steps involve (a) the addition of a small amount, e.g., 2 or 3 ml, of a surface active agent, preferably an anionic long chain alkyl sulfate salt such as sodium dodecyl sulfate, to the sample, immediately after incubation. This stops the reduction reaction producing lysis of the bacterial cells, releasing and solubilizing the formazan, and denaturing the fish protein into a metaprotein to form a clear solution, and (b) the addition of a small amount, e.g., 1 ml, of a short chain aliphatic alcohol, such as methanol, to stabilize the color of the clear formazan solution, apparently by destroying any residual enzyme activity.
The intensity of the color of the solution is compared by a visual colorimetric comparison with control color strips representative of known concentrations of formazan solution ranging from substantially-colorless, for a product of excellent quality, light reddish color representing good quality, darker red color representing borderline quality, and intense red color representing unacceptable quality. These control colors are preliminarily determined by known traditional methods used to measure the bacterial content of finfish of excellent, good, borderline and unacceptable freshness, such as total plate count determination, trimethylamine (TMA) determination, and sensory (odor) determination. Such traditional methods are reliable but are limited in that they require specialized analytical laboratory equipment and/or highly trained personnel, and are either too expensive or time-consuming for the routine analysis of fish. More importantly, most of these traditional methods are not practical or possible in-situ on a fishing boat or at dockside.
In the case of finfish having dark-colored flesh, such as tuna fish, which contain red pigment in the muscle flesh, a final step must be applied, prior to the color comparison of the solution with the control color strips. This involves the addition of a small amount of a bleaching or decoloring agent such as hydrogen peroxide (H 2 O 2 ) and a defoaming agent, such as a dilute silicone emulsion, which is added to dissipate the considerable foam which is generated by the release of oxygen during the bleaching reaction. This step may be integrated with step (b) whereby the surface active agent is added to the sample immediately after incubation and allowed to stand for another 15 minutes. Then the aliphatic alcohol, the bleaching agent and the defoamer must be added to the solution in successive order, with the solution being shaken between each addition, to bleach the colored pigments present in the tuna muscle so that any color developed during the assay is caused by the reduction of the tetrazolium dye.
The following specific example illustrates the application of the present methods to the evaluation of the quality or the bacterial content of fillets from finfish of various species. The fish fillets were purchased from a local seafood retail outlet about 48 hours after harvest, immediately placed on flaked ice in insulated containers and transported to a laboratory for testing.
EXAMPLE 1
Samples of codfish (Gadus morhua), catfish (Ictalcuru spp), or winter flounder (Pseudopleuronectes americanus), each 25 gm in weight, were massaged by hand with 25 ml of bacterial nutrient broth (1:1 ratio) in a sterile 6"×7" strainer bag until finely divided. 5 ml of filtrate or extract from the bag were mixed with 1 ml of indicator dye reagent (2,3,5-triphenyl tetrazolium chloride) in a sterile culture tube. The tube was allowed to stand for 15 minutes at room temperature and shaken by hand vigorously at 5 minute intervals. 2 ml (3 ml for catfish) of Reagent A (10% aqueous sodium dodecyl sulfate-surface active agent) were added to the tube to stop the reaction, followed by 1 ml of Reagent B (methanol-color stabilizer). The color developed in the tube was determined using the Pantone® Professional Color Chart, in which each color is given a numerical percentage value depending upon its intensity.
Samples in two broths were evaluated, "GNA" and "GNP". "GNA" is formulated according to DIFCO protocol for Plate Count Agar (DIFCO Manual, Tenth Edition). "GNP" is a non-protein broth, a mixture of two salts adjusted to pH7, does not need autoclaving and has added stability, and hence, increased shelf life. These two features are very important in terms of manipulation. The % color intensity readings obtained using the present method were plotted against readings obtained using the other traditional methods of analysis. The degree of correlation between the traditional methods and the present method was calculated using regression analysis. High R/2 values mean that the present method correlates favorably with the other traditional method.
A microbiological determination was made using samples from the 1:1 diluted filtrate in each strainer bag which were serially diluted in 0.1% peptone and subjected to microbiological analysis. Total aerobic plate counts were conducted on standard plate count agar incubated at 25° C. for 48 hours before counting. Pseudomonas putrefaciens plate counts were conducted on peptone iron agar incubated at 25° C. for 48 hours. APC and Pseudomonas putrefaciens values were expressed as mean log CFU/g of 10 fillets per sampling day.
A trimethylamine determination was made using samples of fish tissue which were subjected to trimethylamine determination (TMA) using a modification of the procedure of Dyer published in the Journal Fish. Res. Bd Canada, Vol. 6, pp 351-358 (1945).
At each period when samples of fish fillets were removed for microbiological and chemical analyses, a sample of fillet was placed in a plastic bag, vacuum packed, and stored at -20° C. until the end of the study. The vacuum packed fillets were then packed in dry ice and sent overnight to the National Sensory Branch of the National Marine Fisheries Service, Inspection Division, Parker Street, Gloucester, Mass., for sensory analysis.
Samples were subjected to sensory evaluation by trained panelists using a "1" to "10" unstructured line scale, with "1" representing highest quality and "10" the lowest quality. These judges were trained to determine the quality factors of seafood and seafood products based on appearance, texture and odor. Any quality factor(s) indicative of taint or decomposition, regardless of the amount of sample affected, resulted in the sample being failed, i.e., score >5. To fail a sample, the quality factors had to be both persistent and distinct.
FIGS. 1 to 14 of the attached drawings show the relationship between color intensity and days of storage in ice, log. total aerobic plate counts, log. Pseudomonas putrefaciens plate counts, trimethylamine and sensory evaluation of codfish (FIGS. 1 to 5), catfish (FIGS. 6-9) and flounder (FIGS. 10-14). As indicated, for codfish, color was detected between 5 and 7 days of ice storage (FIG. 1). At this stage of detection, log. total aerobic plate count ranged from 6.3 to 7.0 (FIG. 2), whereas log. Pseudomonas putrefaciens count ranged from 4.0 to 5.0 (FIG. 3). This represented trimethylamine (TMA) levels of between 0.34 and 0.57 mg/100 g fish (FIG. 4). Sensory evaluation data (FIG. 5) using the "1" to "10" unstructured line scale indicate that using the present method of evaluation, the cod fish fillets can be assessed according to four categories of quality. These were premium quality (high)-representing up to 5 days of ice storage, (no color detected) with scores ranging from 1.0 to 2.9, high/medium (a stage of low color intensity), with scores ranging from 3.0 to 3.9, fair/medium (intermediate color intensity), and with scores >5.0 representing low/failure quality (intense red). Scores above 5.0 indicate that the sample is considered decomposed to the point of failure.
The relationship between other quality indicators of catfish quality and the present method are shown in FIGS. 6-9. According to FIG. 6, a significant appearance in color was detected between days 5 and 6 of ice storage. At this stage, log. total aerobic plate count ranged from 7.2 to 7.4 (FIG. 7), whereas log. P. putrefaciens count range from 6.0 to 6.2 (FIG. 8). Average sensory score from days 1-5 of ice storage ranged from 2.0 to 3.6, and for days 10-12 (the rejection period) ranged from 6.2 to 8.8 (FIG. 9).
FIGS. 10-14 show the relationship between the various indicators of flounder quality and color score from the present method. In this study, color change was detected between days 3 and 4 of ice storage (FIG. 10), when log. total aerobic plate count (FIG. 11) ranged from 6.2 to 6.6, and log P. putrefaciens count ranged from 5.0 to 5.3 (FIG. 12). At this stage, trimethylamine level was 0.59 mg/100 g fish (FIG. 13). Sensory data (FIG. 14) also showed four stages of quality: High, which ranged from days 1-3 of ice storage; high-medium, days 4-5; medium, days 5-7; and low quality, days 7-10.
The present color test is a simple, rapid, reliable method for the assessment of finfish decomposition during ice storage. The method shows good correlation with other existing methods used to determine fish quality. Other advantages include: minimal sample preparation, ready to use sample reagents, room temperature testing, room temperature storage of reagents and easy disposal of waste materials.
The present method can be used in assessing critical control points for seafood quality. Although development was conducted using fish fillets stored in ice, the method could be adapted for use on whole and dressed fish stored in ice provided that proper sampling procedures are carried out, and the instructions provided in the kit followed closely.
The novel method of the present invention provides a rapid, accurate, in-situ system for evaluating the bacteria content of finfish as a measure of the degree of decomposition and value thereof since the present method yields results which correlate favorably with the results obtained using the traditional tests.
The reagents used in the present method include a water-soluble indicator reagent which undergoes a reduction reaction with the functioning electron transport system of viable bacteria present in the fish broth sample to deposit a water-insoluble red-colored reaction product within the bacterial cell.
The preferred indicator reagents are ionized 2,3,5-triphenyl tetrazolium halide salts, which react with bacteria commonly found in spoiled fish, such as Pseudomonas putrefaciens. The preferred salt is 2,3,5-triphenyl tetrazolium chloride.
The next important reagent, Reagent A, is a water-soluble surface active agent which produces lysis or rupture of the bacterial cells, releasing and solubilizing the formazan dye, and denaturing the fish protein to form a clear solution. The preferred surfactants are the anionic long chain alkyl alkaline earth metal sulfate surfactants or detergents such as sodium dodecyl sulfate.
The next important reagent, Reagent B, is an aliphatic alcohol having from 1 to 4 carbon atoms, preferably methanol, which functions to stabilize the color of the dissolved formazan dye, apparently by destroying any residual enzyme activity.
In the case of finfish having dark-colored or reddish flesh or muscle tissue, such as tuna fish, two additional reagents are required. The first, Reagent C, is a water-soluble bleaching agent which functions to oxidize and decolorize the red pigment present in the muscle flesh of tuna fish, such as hydrogen peroxide. The second additional reagent, Reagent D, is a defoaming agent which dissipates the foam generated by the bleaching reaction. Preferred reagents D are silicone defoamers such as dilute aqueous emulsions of dimethyl silicone.
It will be apparent to those skilled in the art in the light of the present disclosure that a wide variety of colorless, color-forming triphenyl tetrazolium dye salts are suitable for use as the indicator reagents in the present process, as well as a wide variety of other surface active agents, bleaching agents and defoaming agents.
It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims. | A rapid, on-site method for indicating the degree of spoilage, if any, of finfish by the level of bacteria present therein. A small quantity of flesh is cut from a representative fish and kneaded in a bacterial nutrient broth to extract any bacteria present. A triphenyl tetrazolium dye is added as an indicator reagent, followed by an anionic surfactant and a lower alkyl alcohol. The developed color, if any, is compared to a control color chart representative of acceptable and unsatisfactory degrees of bacterial contamination or spoilage. | 2 |
TECHNICAL FIELD
The present invention relates to improvements in and/or relating to the synchronising of animal oestrus and intra vaginal devices useful therein together with related means and methods.
BACKGROUND ART
It is useful for farmers to synchronise the oestrus of animals whether they be cattle beasts (whether for dairy or beef purposes) sheep, goats, horses, or the like where artificial insemination is practised. By way of example, in relation to cattle beasts, in a normal 365 day year 282 days on average is taken up of the year with the gestation period itself. With approximately 30 days to recover after delivery of its progeny each cow therefore has an average of only two and a half cycles if there is to be a timely management of the herd. Thus it is important over that remaining period of less than 53 days to ensure each cow in a herd becomes pregnant.
The traditional method of mating dairy cows with bulls is now largely superseded by the use of artificial insemination procedures which offer the prospect of rapid herd improvements although bulls are still presented to the herd frequently to catch those animals that have not conceived by the artificial insemination procedure.
There is therefore a great advantage attached to bringing such herd animals into oestrus simultaneously so as to make it easier to ensure effective usage of the artificial insemination procedure and subsequently to enable still within the “window” a further prospect of artificial insemination of those animals synchronistically brought to oestrus that have not already conceived.
Various means of achieving such a management of the synchronisation of the coming into oestrus of cows (whether heifers or lactating cows) and even sheep and goats has been disclosed in the art which includes the “EAZI-BREED CIDR Controlled Breeding and Reproductive Management” booklet made available to interested parties by InterAg a division of the applicant company in respect of its intra vaginal Eazi-Breed™ CIDR R product line.
The disclosures in the aforementioned publication, the fill contents of which are here included by way of reference, comprehensively describe treatment protocols applicable at least to New Zealand herds of cattle beasts for synchronising oestrus and treatment of anoestrus.
These treatment protocols often utilise Eazi-Breed™ CIDR R devices in combination with drugs such as prostaglandin and/or oestradiol benzoate, and extend in general for periods of 7, 10 or 12 days.
If both control of the oestrus cycle and high fertility are to be optimised in cattle, studies have shown that an intra vaginal device must deliver sufficient progesterone (when used with combination drugs i.e. oestradiol or GnRH) to produce a minimum plasma progesterone concentration of 2 ng/mL over the terminal period of treatment (1,2).
1. Kesner, J. S., Padmanabhan, V. and Convey, E. M. Biol. Reprod. 26 (1982) 571-578.
2. Kinder, J. E., Kojima, F. N., Bergfeld, E. G. M., Wehrman, M. E. and Fike, K. E. J.Anim. Sci 74 (1996) 1424-1440.
A cost factor arises in the adoption of such protocols as a farmer is faced with the costs of the intra vaginal progesterone containing device as well as the use of the combination drugs. This ignores also the economic cost of the artificial breeding materials themselves.
The intra vaginal progesterone containing devices hitherto used in New Zealand and to a large extent elsewhere are typified by the CIDR R product of the applicant company depicted hereinafter in FIG. 1 being a variable geometry device for vaginal insertion and retention which comprises a structural frame of a metal or appropnate plastics material encased in a progesterone impregnated plastics material from which the material can leach in the vaginal environment and from which it can be timely withdrawn by appropriate means (e.g: a string, tail or a tool) to allow the animal to progress into oestus shortly after the removal. Hereinafter the aforementioned device will be referred to by its registered trademark CIDR R .
Another product available in the market place of this kind is another variable geometry device and such a device is depicted hereinafter in FIG. 2 . Such a device is a helical coil capable of being helically tightened and which is retainable in its helical form in the animals vagina. The device includes a withdrawal cord and carries a gelatine capsule which includes oestradiol benzoate so that there can be co-administration of the progesterone to be released over a protracted period and the oestradiol benzoate which is to be released at a different rate. Such a device includes a progesterone impregnated plastics matrix about a helical spine. Such a device is available from Sanofi Animal Health Limited, PO Box 209, Rhodes Way, Watford, Herts, WD24QE, England under its registered trademark PRID R .
The aforementioned CIDR R and PRID R devices are manufactured in large volumes with the most expensive material being the progesterone active ingredient and thus small reductions in the progesterone inclusion in such devices will provide an economic advantage to a producer and to a farmer. Also any such reduction provides a reduced risk to the environment owing to a likely reduced residual amount of the progesterone in the matrix after the device has been withdrawn from an animal. This reduced residual amount not only provides safety but also dis-encourages the unrecommended reuse of a device in another animal where the unknown condition of such a device will give unpredictable results.
The CIDR R prior art device of the applicant company has been marketed with a silicone plastics matrix about its spine which contains about 1.9 grams of progesterone (USP) which drops to 1.33 grams still retained in the silicone matrix if the device is withdrawn after seven days. The same device drops to 1.05 grams of progesterone if it is not withdrawn until after 12 days.
The PRID R coil intra vaginal device contains at the outset 1.55 grams of progesterone which reduces down to 1.18 grams after 7 days and down to 0.94 grams after 10 days. The leach rate from the PRID R product may be affected in part by the inclusion of inorganic materials in the silicone plastics material such as calcium carbonate. The CIDR R silicone matrix is largely free of any such inclusions.
Hoechst U.S. Pat. No. 5,398,698 discloses the use of milled sheets of silicone rubber in intra-vaginal devices which carry progesterone. The milled sheets (2 to 10 mm thick) are vulcanised for from 4 to 8 minutes at from 70° C. to 120° C.
The accepted test for the delivery of progesterone or its metabolites to the appropriate site of action in order to postpone oestrus is by reference to the progesterone level in the blood plasma of the animal. The design of such devices has to date usually been on the basis of an acceptance of the Higuchi equation based on a square root of time model (see hereinafter) which suggests that progesterone inclusions in such a plastics matrix would achieve plasma levels which decline with time.
Our investigations have found surprisingly that it is inappropriate in the design of such intra vaginal devices to rely upon the Higuchi equation or the square root of time model. In our device release is constant with time up to 7 days resulting in constant steady state plasma levels over that time period.
We have determined that by modifying the levels of progesterone initially in a silicone matrix, by controlling the thickness of the silicone matrix over the spine and by giving attention to the surface area of the device savings to a manufacturer arising from reduced quantities of progesterone being needed while at the same time achieving the same blood levels can be achieved. Savings are also achieved over the prior art devices in terms of the amount of silicone used, since silicone is the second-most costly material used in the devices, with corresponding benefits being able to be passed on to the user.
The present invention relates to intra vaginal devices, methods of producing intra vaginal devices, and the use of such intra vaginal devices for managing oestrus and for the treatment of anoestrus in cattle, sheep, deer and goats.
DISCLOSURE OF INVENTION
In one aspect the invention is an intra vaginal device of a variable geometry kind capable of being applied into the vaginal cavity of an animal selected from the group consisting of cattle, sheep, deer and goats, retainable therein over a period of time within the range of from 7 to 12 days and then to be withdrawable therefrom to allow the onset of oestrus, said device being characterised in that:
a matrix of a cured silicone rubber material that includes greater than 5% by weight progesterone to the weight of the matrix defines an exterior surface (which may be all or part only of the device) of at least 75 cm 2 contactable once inserted in the vagina of such an animal by the vaginal membrane and/or vaginal fluid(s) of the animal,
the matrix of progesterone containing silicone rubber material has been formed by injection of the uncured progesterone containing matrix as a liquid into a mould for a sufficient time to achieve at a mould temperature or temperatures within the range of from 100° C. to 210° C. and a shape retaining at least partial cure thereof,
the total progesterone load (irrespective of whether alpha or beta progesterone or mixtures thereof) being from 1 to 1.5 grams within said matrix,
said surface area is available to at least substantially all of the matrix for progesterone release over a thickness of no greater than about 1 millimeter, and
said device upon vaginal insertion into such an animal is able to achieve and then maintain in the animal for a least seven days a minimum progesterone blood plasma level of 2 nanograms per milliliter of plasma of the animal and which after seven days of insertion will have a residual load in the silicone rubber matrix of less than 65% by weight of its progesterone load at insertion.
Preferably said exterior surface is from 100 to 150 cm 2 , more preferably 120 to 125 cm 2 .
Preferably said matrix has about 10% by weight progesterone by weight of progesterone to the weight of matrix.
Preferably said matrix at least in part encases a deformable frame.
Preferably said frame is resilient.
Preferably said frame is substantially in the form of a “T” with the arms of the “T” being deformable to allow introduction into the vagina of an animal, the “T” form being defined by a resilient spine about which (at least in part) there is moulded said matrix.
Preferably said frame is of nylon.
Preferably after seven days from insertion the matrix will have a residual load of less than 60% by weight of its progesterone load at insertion.
In a further aspect the invention is an intra vaginal device of a variable geometry kind capable of being applied into the vaginal cavity of an animal selected from the group consisting of cattle, sheep, deer and goats, retainable therein over a period of time within the range of from 7 to 12 days and then to be withdrawable therefrom to allow the onset of oestrus, said device being characterised in that
on a frame or spine (hereafter “frame”) of variable geometry there is a matrix of a cured silicone rubber material that includes greater than 5% and less than 20% by weight progesterone to the weight of the matrix defines and exterior surface (which may be all or part only of the device) of at least 100 cm 2 contactable once inserted in the vagina of such an animal by the vaginal membrane and/or vaginal fluid(s) of the animal,
the matrix of progesterone containing silicone rubber material has been formed by injection of the uncured progesterone containing matrix as a liquid into a mould for a sufficient time to achieve at a mould temperature of temperatures within the range of from 190° C. to 195° C. and a shape retaining at least partial cure thereof,
the total progesterone load (irrespective of whether alpha or beta progesterone or mixtures thereof) being from 1 to 1.5 grams (preferably about 1.35 grams) within said matrix,
said surface area is available to at least substantially all of the matrix for progesterone release over a thickness of no greater than about 1 millimeter, and
said device upon vaginal insertion into such an animal is able to achieve and then maintain in the animal for at least seven days a minimum progesterone blood plasma level of 2 nanograms per milliliter of plasma of the animal and which after seven days from insertion will have a residual load in the silicone rubber matrix of less than 65% by weight of its progesterone load at insertion.
Preferably said device is substantially as herein defined with reference to any one or more of the accompanying drawings.
In still a further aspect the invention a method of postponing oestrus or treatment of anoestrus in an animal which includes the steps of
administering into said animal by means of an intra vaginal device sufficient progesterone from a progesterone impregnated silicone rubber matrix where the progesterone content in the matrix is 5% or greater by weight via a surface area greater than 75 cm 2 so as to achieve on the last few days of insertion a progesterone blood plasma level of greater than 2 nanograms per milliliter, and
removing the device after an insertion period of from 7 to 12 days.
Preferably said device is as previously defined.
Preferably said method includes the administration of oestradiol at or near the time of insertion of said device.
Preferably said method includes the administration of a prostaglandin at about day 6 of about a 7 to 10 day device insertion period.
In still a further aspect the invention is, in a method of attempting to synchronise the onset of oestrus of a herd of cattle beasts, the procedure of
administering intra vaginally to each animal of the herd progesterone from an intra vaginal device of the present invention and
after an appropriate period of time removing such devices to allow the onset of oestrus (the procedure optionally including the steps of administration of oestradiol benzoate and/or prostaglandin etc. as known in the art or otherwise), said method being further characterised in that levels of progesterone in the blood plasma of each animal is greater than 2 nanograms per milliliter until such time as the devices are withdrawn.
In still a further aspect the invention consists in a method of synchronising the onset of oestrus in a herd of cattle beasts which comprises
administering by means of an intra vaginal device to each animal from a progesterone impregnated matrix of the device an effective amount of progesterone for the period the device is retained intra vaginally, the device having being administered with a progesterone quantity of about 1.35 grams and being removed with a progesterone quantity of the order of about 0.85 grams.
As used here in “surface area” of the progesterone impregnated matrix is that area directly contactable by vaginal fluid(s) and/or membrane.
As used herein “surface area” is independent of any surface area of the spine (if any) which may or may not be of a plastics material. However, thicknesses of the progesterone impregnated medium or matrix are to the surface of the spine.
While reference has been made to cattle beasts the device and method is believed to be equally applicable to other mammals, e.g. sheep, goat, horse, etc.
BRIEF DESCRIPTION OF DRAWINGS
The present invention will now be described with reference to the accompanying drawings in which:
FIG. 1 shows a series of drawings (a) through (e) of a prior art EaziBreed™ CIDR™ product of this company having a progesterone impregnated silicone matrix of an average depth of about 1.5 mm but having the depth thereof varying greatly,
FIG. 1A is an elevation of the “T” shaped device capable of having the top arms thereof resiliently bent to alongside the upstanding body during insertion with an appropriate applicator pull and capable of assuming some return to the “T” form so as to be retained within the vagina of an appropriate animal such as a cattle beast,
FIG. 1B is a section at “FF” of the top arms of the “T” form,
FIG. 1C is a section at “DD” of the body,
FIG. 1D is a view “CC” of the end of the body showing a slot formed therein from a hole through the body so as to allow the lying therein of a retained withdrawal string or other device,
FIG. 1E is a section of the body at “EE”.
FIG. 1 ′ shows the preferred spine of the prior art device, a spine which with no or little modification is useful in a device in accordance with the present invention,
FIG. 1 ′A shows an elevation of the spine,
FIG. 1 ′B showing a side elevation of the spine,
FIG. 1 ′C showing the plan view of the top arms of the device,
FIG. 1 ′D shows the section at “AA”,
FIG. 1 ′E shows the section at “BB”,
FIG. 2 shows the PRID™ device previously referred to,
FIG. 3 shows a preferred device in accordance with the present invention having an average progesterone impregnated matrix of about or less than 1 mm thick over a spine of a kind shown in FIG. 1 ′,
FIG. 3A shows an elevation of the (CIDR-B™) device in accordance with the present invention,
FIG. 3B shows the side elevation of the device of FIG. 3A,
FIG. 3C shows a plan view of the top of the device as shown in FIGS. 3A and 3B,
FIG. 3D shows a section at “DD” of FIG. 3A,
FIG. 3E shows a section at “CC” of FIG. 3A,
FIG. 3F shows a section at “BB” of FIG. 3A,
FIG. 3G shows a section at “AA” of FIG. 3A,
FIG. 3H shows a section at “PP” of FIG. 3A, being the hinging region of the arms from the body, and
FIG. 3I is the section “HH” of FIG. 3A, and
FIGS. 4 through 15 show results, plots, models and concepts hereinafter described in greater detail.
DETAILED DESCRIPTION
The device of the present invention will now be described with reference to both in vitro and in vivo studies. In the following description the reference to the CIDR™ device is by reference to the device of the form depicted in FIGS. 1A to 1 E. The reference hereafter to the device of the present invention (to be known as the CIDR-B™ device) is preferably that substantially as depicted in FIGS. 3A through 3I and described hereinafter in more detail.
In Vitro Studies
The in vitro release assessment method for the existing CIDR™ device was based on the equipment and general procedures documented in the US Pharmacopoeia, XXIII pp 1791-1975 (1995). In vitro release of progesterone from the device followed a declining profile with time (FIG. 4 ).
Mechanism of Release
Release data was plotted as cumulative amount of progesterone released per unit area versus square-root-of-time. The release profile over greater than 75% of total release from the existing CIDR™ device followed a square-root-of-time model (FIG. 5; linear dependence of progesterone release as a function of the square root of time).
Effect of Drug Load
Release rate was observed to be affected by initial drug load as expected from the square-root-of-time model (FIG. 6 : linear dependence of progesterone release rate as a function of the square root of twice the amount of initial drug load).
Determination of the Depletion Zone within Silicone
Depletion zone determinations clearly showed the formation of a depletion zone in the silicone skin (FIG. 7) which is consistent with the square-root-of-time theory (FIG. 8 ).
The results of all in vitro experiments conducted on the CIDR™ device suggested that progesterone was being released from the silicone matrix according to the square-root-of-time model of release.
In Vivo Studies
The following in vivo studies which led to our discoveries were conducted on the existing CIDR™ device and on devices of the present invention (i.e., devices referred to as the CIDR-B™ devices).
Blood level Parameter (Steady-state Blood Level)
Following insertion of the existing CIDR™ device into ovariectomized cattle a characteristic plasma profile was observed (FIG. 9 ). There was a rapid absorption phase. Blood levels peaked within a few hours. The peak level was sustained for 48 hours before it fell over the following 24 to 48 hours to levels which were constant or diminished only very slightly over the remaining 4 days of the 7 day insertion period (apparent steady-state levels). Following removal of the device, plasma levels fell rapidly to basal levels. Based on FIG. 9 we selected average progesterone steady-state plasma levels over the last four days of a 7 day insertion period as the performance indicator of the device.
Effect of Initial Progesterone Concentration
The effect of initial progesterone concentration in the device on the average progesterone steady-state plasma levels over the last four days of a 7 day insertion period is shown in FIG. 10 . FIG. 10 shows that the devices containing above a 5% w/w initial progesterone concentration produce average progesterone steady-state plasma levels over the last four days of a 7 day insertion period above 2 ng/mL.
Effect of Surface Area
The effect of surface area upon the average progesterone steady-state plasma levels over the last four days of a 7 day insertion period is shown in FIG. 11 . An increase in surface area produced an increase in average progesterone steady-state plasma levels over the last four days of a 7 day insertion period (FIG. 11 ). A surface area of greater than 75 cm 2 is required to ensure that average progesterone steady-state plasma levels over the last four days of a 7 day insertion period are above 2 ng/mL.
Determination of the Depletion Zone within Silicone of Used Devices
Progesterone concentration at various depths of a spent existing device that had been inserted for 7 days in cattle is shown in FIG. 12 . FIG. 12 shows clearly that no distinct depletion zone was apparent following removal of the device after a 7 day insertion period in the vagina of cattle (cf. the clear depletion zone which was observed in the in vitro experiments; FIG. 7 ). Indeed following in vivo insertion the 0-0.5 mm outermost layer of silicone rubber skin still contained drug but at a concentration less than that originally incorporated into the device, the 0.5-1.0 mm layer also still contained drug but at a concentration less than that originally incorporated into the device. Beyond 1 mm the original amount of progesterone incorporated into the device was detected (FIG. 12 ). These results (FIG. 12) clearly demonstrate that progesterone was only eluted out of the first 1 mm of silicone rubber skin. The results also suggest that no distinct depletion zone forms as the drug is being released while the device is inside the animal but instead as release occurs a gradation of solid particles forms within the first 1 mm of skin. Possible reasons why such observations were detected are shown in FIG. 13 . These observations are not consistent with the square-root-of-time model. Indeed, the in vivo release of progesterone from the device was observed to be constant with time (FIG. 14) and follow a zero-order release mechanism (cf. the declining profile when the amount of progesterone released from the CIDR-B in vitro was plotted against time; FIG. 4 ).
Investigations on a Device of the Present Invention
From these studies a device was manufactured which had a uniform silicone rubber skin thickness of <1 mm, surface area of 120 cm 2 and initially contained 1.25 g (10% w/w) of progesterone. FIG. 15 shows the average progesterone steady-state plasma levels over the last four days of a 7 day insertion period determined for the existing CIDR device and a device in accordance with the present invention (CIDR-B device). FIG. 15 clearly shows that the CIDR-B device is able to effectively sustain progesterone steady-state plasma levels over the last four days of a 7 day insertion period above 2 ng/mL. In addition, the final:initial content ratio for the CIDR-B device is less than 60% following a 7 day insertion period (Table 1).
TABLE 1
Comparison of the initial amount of progesterone, residual progesterone in spent devices and
amount of progesterone released from existing CIDR ™ device and device (CIDR-B ™ device)
which has characteristics described in this patent application following removal after 7 days.
Initial
Initial amount
Residual amount
Amount of
progesterone
of
of progesterone
progesterone
Intra vaginal
concentration
progesterone
remaining in
released over 7
progesterone
in device
in device
device
days
Final:Initial
release device
(% w/w)
(g)
(g)
(g)
ratio
Existing CIDR ™
10
1.92
1.36
0.56
0.71
device
Device of the
10
1.25
1.36
™ 0.56
0.59
present invention
(CIDR-B ™)
The following table of in vivo comparative data compares a device in accordance with the present invention (CIDR-B™) with a CIDR™ device and a PRID™ device.
In Vivo Comparisons
Existing
New CIDR-B ™
CIDR ™
device
PRID ™
Parameter
device
(Present invention)
DEVICE
At least 10%
Yes (10%)
Yes (10%)
No
Progesterone in skin
(Approx. 7.5%)
Progesterone
Yes
Yes
Yes
bloods > 2 ng/mL
for at least 7 days
Initial Progesterone (g)
1.9
1.35
1.55
Final Progesterone
1.3
0.8
1.18
(7 days)
Final Progesterone
1.18
0.63
0.94
(10 days)
Final/Initial (7 days)
0.68
0.59
0.76
Final/Initial (10 days)
0.62
0.47
0.61
Skin thickness (mm)
Variable
1.0
1.0
(0.9-5)
Surface area (cm 2 )
120
120
220
The Device of the Present Invention (CIDR-B™)
The device (CIDR-B™) consists of a progesterone impregnated silicone elastomer skin moulded over an inert nylon spine. The active ingredient of the device is micronised USP natural progesterone. Device potency is determined by the percentage of active ingredient present in the inactive silicone elastomer.
The progesterone is mixed into each of two liquid silicone parts prior to the silicone being introduced to the machine for moulding. The progesterone is preferably mixed in at 10% by total weight.
At the moulding stage the two parts of the liquid silicone are pumped under pressure of approximately 100 bar from pails into the injection chambers of an injection moulding machine. Upon injection, the two parts of silicone are simultaneously forced through a static mixer before flowing into an electrically heated mould.
The nylon spine is inserted into the mould prior to the silicone being injected. The mould has a die surface temperature of typically 190°-195° C., but preferably never exceeding 200° C. The mould is kept clamped shut under approximately 30 tonnes of static pressure while the silicone cures. At the indicated temperature and pressure, the liquid silicone takes approximately 50 seconds to cure into a rubber.
Following curing, the finished product is removed from the mould and cooled before packaging.
The surface area of the silicone skin is approximately 120-125 cm 2 with the typical formulation for the device being:
Nominal
Outer Skin
Weight
Percentage of
Percentage of
(Impregnated Matrix)
(gm)
Skin
Device
Active progesterone USP
1.35
10%
5.1%
Inactive silicone elastomer
12.15
90%
45.9% | An intra vaginal device which is of a variable geometry and which includes a silicone matrix impregnated with progesterone, the confirmation and content of the progesterone impregnated matrix being such as to optimize effectiveness with a lower initial loading of progesterone. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a Division of copending application Ser. No. 11/133,074 filed May 19, 2005, the contents of which are hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] Copper containing materials are widely used in industry as catalysts and sorbents. The water shift reaction in which carbon monoxide is reacted in presence of steam to make carbon dioxide and hydrogen as well as the synthesis of methanol and higher alcohols are among the most practiced catalytic processes nowadays. Both processes employ copper oxide based mixed oxide catalysts.
[0003] Copper-containing sorbents play a major role in the removal of contaminants, such as sulfur compounds and metal hydrides, from gas and liquid streams. One new use for such sorbents involve the on-board reforming of gasoline to produce hydrogen for polymer electrolyte fuel cells (PEFC). The hydrogen feed to a PEFC must be purified to less than 50 parts per billion parts volume of hydrogen sulfide due to the deleterious effects to the fuel cell of exposure to sulfur compounds.
[0004] Copper oxide (CuO) normally is subject to reduction reactions upon being heated but it also can be reduced even at ambient temperatures in ultraviolet light or in the presence of photochemically generated atomic hydrogen.
[0005] The use of CuO on a support that can be reduced at relatively low temperatures is considered to be an asset for some applications where it is important to preserve high dispersion of the copper metal. According to U.S. Pat. No. 4,863,894, highly dispersed copper metal particles are produced when co-precipitated copper-zinc-aluminum basic carbonates are reduced with molecular hydrogen without preliminary heating of the carbonates to temperatures above 200° C. to produce the mixed oxides.
[0006] However, easily reducible CuO is disadvantageous in some important applications. The removal of hydrogen sulfide (H 2 S) from gas streams at elevated temperatures is based on the reaction of CuO with H 2 S. Thermodynamic analysis shows that this reaction results in a low equilibrium concentration of H 2 S in the product gas even at temperatures in excess of 300° C. The residual H 2 S concentration in the product gas is much higher (which is undesirable) when the CuO reduces to Cu metal in the course of the process since reaction (1) is less favored than the CuO sulfidation to CuS.
2Cu+H 2 S═Cu 2 S+H 2 (1)
Therefore, a reduction resistant CuO sorbent would be more suitable for exhaustive removal of H 2 S from synthesis gas assuring a purity of the H 2 product that is sufficient for fuel cell (PEFC) applications.
[0007] Copper oxide containing sorbents are well suited for removal of arsine and phosphine from waste gases released in the manufacture of semiconductors. Unfortunately, these gases often contain hydrogen, which in prior art copper oxide sorbents has triggered the reduction of the copper oxide. The resulting copper metal is less suitable as a scavenger for arsine and phosphine. A further detriment to the reduction process is that heat is liberated which may cause run away reactions and other safety concerns in the process. These facts are other reasons that it would be advantageous to have a CuO containing scavenger that has an improved resistance towards reduction.
[0008] Combinations of CuO with other metal oxides are known to retard reduction of CuO. However, this is an expensive option that lacks efficiency due to performance loss caused by a decline of the surface area and the lack of availability of the CuO active component. The known approaches to reduce the reducibility of the supported CuO materials are based on combinations with other metal oxides such as Cr 2 O 3 . The disadvantages of the approach of using several metal oxides are that it complicates the manufacturing of the sorbent because of the need of additional components, production steps and high temperature to prepare the mixed oxides phase. As a result, the surface area and dispersion of the active component strongly diminish, which leads to performance loss. Moreover, the admixed oxides are more expensive than the basic CuO component which leads to an increase in the sorbent's overall production cost.
[0009] The present invention comprises a new method to increase the resistance toward reduction of CuO powder and that of CuO supported on a carrier, such as alumina. Addition of a small amount of a salt, such as sodium chloride (NaCl) to the basic copper carbonate (CuCO 3 .Cu(OH) 2 ) precursor, followed by calcination at about 400° C. to convert the carbonate to the oxide, has been found to significantly decrease the reducibility of the final material. An increase of the calcination temperature of BCC beyond the temperature needed for a complete BCC decomposition also has a positive effect on CuO resistance towards reduction, especially in the presence of Cl.
[0010] Surprisingly, it has now been found that calcination of intimately mixed solid mixtures of basic copper carbonate (abbreviated herein as “BCC”) and NaCl powder led to a CuO material that was more difficult to reduce than the one prepared from BCC in absence of any salt powder.
SUMMARY OF THE INVENTION
[0011] The present invention offers a method to increase the resistance of CuO and supported CuO materials against reduction by the addition of small amounts of an inorganic halide, such as sodium chloride to basic copper carbonate followed by calcinations for a sufficient time at a temperature in the range 280 to 500° C. that is sufficient to decompose the carbonate. These reduction resistant sorbents show significant benefits in the removal of sulfur and other contaminants from gas and liquid streams.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Basic copper carbonates such as CuCO 3 .Cu(OH) 2 can be produced by precipitation of copper salts, such as Cu(NO) 3 , CuSO 4 and CuCl 2 , with sodium carbonate. Depending on the conditions used, and especially on washing the resulting precipitate, the final material may contain some residual product from the precipitation process. In the case of the CuCl 2 raw material, sodium chloride is a side product of the precipitation process. It has been determined that a commercially available basic copper carbonate that had both residual chloride and sodium, exhibited lower stability towards heating and improved resistance towards reduction than another commercial BCC that was practically chloride-free.
[0013] In some embodiments of the present invention, agglomerates are formed comprising a support material such as alumina, copper oxide and halide salts. The alumina is typically present in the form of transition alumina which comprises a mixture of poorly crystalline alumina phases such as “rho”, “chi” and “pseudo gamma” aluminas which are capable of quick rehydration and can retain substantial amount of water in a reactive form. An aluminum hydroxide Al(OH) 3 such as Gibbsite, is a source for preparation of transition alumina. The typical industrial process for production of transition alumina includes milling Gibbsite to 1-20 microns particle size followed by flash calcination for a short contact time as described in the patent literature such as in U.S. Pat. No. 2,915,365. Amorphous aluminum hydroxide and other naturally found mineral crystalline hydroxides e.g., Bayerite and Nordstrandite or monoxide hydroxides (AlOOH) such as Boehmite and Diaspore can be also used as a source of transition alumina. In the experiments done in reduction to practice of the present invention, the transition alumina was supplied by the UOP LLC plant in Baton Rouge, La. The BET surface area of this transition alumina material is about 300 m 2 /g and the average pore diameter is about 30 Angstroms as determined by nitrogen adsorption.
[0014] Typically a solid oxysalt of a transitional metal is used as a component of the composite material. “Oxysalt”, by definition, refers to any salt of an oxyacid. Sometimes this definition is broadened to “a salt containing oxygen as well as a given anion”. FeOCl, for example, is regarded as an oxysalt according this definition. For the purpose of the examples presented of the present invention, we used basic copper carbonate (BCC), CuCO 3 Cu(OH) 2 which is a synthetic form of the mineral malachite, produced by Phibro Tech, Ridgefield Park, N.J. The particle size of the BCC particles is approximately in the range of that of the transition alumina-1-20 microns. Another useful oxysalt would be Azurite—Cu 3 (CO 3 ) 2 (OH) 2 . Generally, oxysalts of copper, nickel, iron, manganese, cobalt, zinc or a mixture of elements can be successfully used.
[0015] In the present invention, a copper oxide sorbent is produced by combining an inorganic halide with a basic copper carbonate to produce a mixture and then the mixture is calcined for a sufficient period of time to decompose the basic copper carbonate. The preferred inorganic halides are sodium chloride, potassium chloride or mixtures thereof. Bromide salts are also effective. The chloride content in the copper oxide sorbent may range from 0.05 to 2.5 mass-% and preferably is from 0.3 to 1.2 mass-%. Various forms of basic copper carbonate may be used with a preferred form being synthetic malachite, CuCO 3 Cu(OH) 2 .
[0016] The copper oxide sorbent that contains the halide salt exhibits a higher resistance to reduction than does a similar sorbent that is made without the halide salt. The copper oxide sorbent of the present invention is particularly useful in removing arsenic, phosphorus and sulfur compounds from gases or liquids. It is particularly useful in removing the arsine form of arsenic that poisons the catalyst even when this impurity is found in very low concentrations in olefin feeds used for polymer production.
[0017] Table 1 lists characteristic composition data of three different basic copper carbonate powder samples designated as samples 1, 2 and 3.
TABLE 1 Composition, Sample Number Mass-% 1 2 3 Copper 55.9 55.4 54.2 Carbon 5.0 5.1 5.1 Hydrogen 1.3 1.2 1.2 Sodium 0.23 0.51 0.51 Chloride 0.01 0.32 0.28 Sulfate 0.06 0.01 0.02
[0018] All three samples were subjected to thermal treatment in nitrogen in a microbalance followed by reduction in a 5% H 2 -95% N 2 stream. As the thermogravimetric (TG) analysis showed, chloride-containing BCC samples 2 and 3 decompose to CuO at about 40° to 50° C. lower temperatures than sample 1. On the other hand, the latter sample was found to reduce more easily in presence of H 2 than the Cl-containing samples. The reduction process completed with sample 1 at 80° to 90° C. lower temperature than in the case of the Cl-containing samples “2” and “3” The TG experiment was carried out with a powder sample of about 50 mg wherein the temperature was ramped to 450° C. at a rate of increase of 10° C. per minute followed by a 2 hour hold and then cooling down to 100° C. A blend of 5% H 2 with the balance N 2 was then introduced into the microbalance and the temperature was increased again at a rate of 10° C. per minute to 450° C. The total weight loss of the samples in N 2 flow reflected the decomposition of BCC to the oxide while the weight loss in the presence of a H 2 —N 2 mixture corresponded to the reduction of CuO to Cu metal.
[0019] In the present invention it has been found that the residual Cl impurity caused the observed change in BCC decomposition. This reduction behavior was confirmed by preparing a mechanical mixture of NaCl and the Cl—free sample 1 sample and then subjecting the mixture to a TG decomposition reduction test. In particular, 25 mg of NaCl reagent was intimately mixed with about 980 mg BCC (sample 1). The mixture was homogenized for about 2 minutes using an agate mortar and pestle prior to TG measurements.
[0020] It was found that the addition of NaCl makes sample 1 decompose more easily but also makes it resist reduction to a higher extent than in the case where no chloride is present. The observed effect of NaCl addition is definitely beyond the range of experimental error.
[0021] The exact mechanism of the chloride action is unknown at this point. We hypothesize that the salt additive may incorporate in some extent in the structure of the source BCC weakening it and making it more susceptible to decomposition. On the other hand, the copper oxide produced upon thermal decomposition of BCC now contains an extraneous species that may affect key elements of the metal oxide reduction process such as H 2 adsorption and activation and penetration of the reduction front throughout the CuO particle as well. We do not wish to favor any particular theory of Cl action at this point.
[0022] The series of experiments in which NaCl was added was conducted in a different TG-setup than that used to generate the data of decomposition without addition to NaCl. The setup consisted of a Perkin Elmer TGA-1 microbalance operated in a helium flow. The sample size was typically 8-10 mg. Both decomposition and reduction runs were conducted with one sample at a heating rate of about 25° C./min followed by short hold at 400° C. After cooling to about ambient temperature, 1.5% H 2 — balance He—N 2 mixture was used as a reduction agent.
[0023] It was found that the Cl treated sample reduced at a temperature which is nearly 100° C. higher than the original untreated BCC sample. It is evident that the reduction process with the former sample does not complete while ramping the temperature to 400° C. With the non-treated samples the reduction concludes at about 350° C. while the sample is still heated up.
[0024] Table 2 presents data on several samples produced by mixing different amounts of NaCl or KCl powder to the BCC sample #1 listed in Table 1. The preparation procedure was similar to that described in paragraph [0019].
TABLE 2 Characteristic Basic Cu temperature, ° C. carbonate, NaCl KCl Pre-treatment BCC CuO Sample (g) (g) (g) temperature, ° C. decomposition* reduction** 1 #1 only 0 0 400 335 256 2 9.908 0.103 0 400 296 352 3 9.797 0.201 0 400 285 368 4 9.809 0.318 0 400 278 369 5 9.939 0 0.150 400 282 346 6 9.878 0 0.257 400 279 378 7 0.981 0 0.400 400 279 382 8 #1 only 0 0 500 333 310 9 9.797 0.201 0 500 282 386 *Temperature at which 20 mass-% sample weight is lost due to BCC decomposition **Temperature at which 5% sample weight is lost due to CuO reduction
The data also shows that both NaCl and KCl are effective as a source of Cl. Adding up to 1% Cl by weight affects strongly both decomposition temperature of BCC and the reduction temperature of the resulting CuO. It can be also seen that the combination of a thermal treatment at a temperature which is higher than the temperature needed for complete BCC decomposition and Cl addition leads to the most pronounced effect on CuO resistance towards reduction—compare samples number 3, 8 and 9 in Table 2.
[0025] Finally, the materials produced by conodulizing the CuO precursor—BCC with alumina followed by curing and activation retain the property of the basic Cu carbonate used as a feed. The BCC that is more resistant to reduction yielded a CuO—alumina sorbent which was difficult to reduce.
[0026] The following example illustrates one particular way of practicing this invention with respect of CuO—alumina composites:
[0000] About 45 mass-% basic copper carbonate (BCC) and about 55 mass-% transition alumina (TA) produced by flash calcination were used to obtain 7×14 mesh beads by rotating the powder mixture in a commercial pan nodulizer while spraying with water.
[0027] About 1000 g of the green beads were then additionally sprayed with about 40 cc 10% NaCl solution in a laboratory rotating pan followed by activation at about 400° C. The sample was then subjected to thermal treatment & reduction in the Perkin Elmer TGA apparatus as described earlier. Table 3 summarizes the results to show the increased resistance towards reduction of the NaCl sprayed sample.
TABLE 3 Characteristic temperature of TGA analysis, ° C. BCC CuO Sample Preparation condition decomposition* reduction** 10 Nontreated 341 293 11 Nontreated + activation n/a 302 12 NaCl treated 328 341 13 NaCl treated + activation n/a 352 *Temperature at which 20 mass-% sample weight is lost due to BCC decomposition **Temperature at which 5% sample weight is lost due to CuO reduction
[0028] A cost-effective way to practice the invention is to leave more NaCl impurity in the basic Cu carbonate during the production. This can be done, for example, by modifying the procedure for the washing of the precipitated product. One can then use this modified BCC precursor to produce the sorbents according to our invention.
[0029] Another way to practice the invention is to mix solid chloride and metal oxide precursor (carbonate in this case) and to subject the mixture to calcinations to achieve conversion to oxide. Prior to the calcinations, the mixture can be co-formed with a carrier such as porous alumina. The formation process can be done by extrusion, pressing pellets or nodulizing in a pan or drum nodulizer.
[0030] Still another promising way to practice the invention is to co-nodulize metal oxide precursor and alumina by using a NaCl solution as a nodulizing liquid. The final product containing reduction resistant metal (copper) oxide would then be produced after proper curing and thermal activation. | Mixing small amounts of an inorganic halide, such as NaCl, to basic copper carbonate followed by calcination at a temperature sufficient to decompose the carbonate results in a significant improvement in resistance to reduction of the resulting copper oxide. The introduction of the halide can be also achieved during the precipitation of the carbonate precursor. These reduction resistant copper oxides can be in the form of composites with alumina and are especially useful for purification of gas or liquid streams containing hydrogen or other reducing agents. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to an improved data processing system and in particular to a method and apparatus for enabling a workaround to bypass errors or other anomalies in the data processing system.
[0003] 2. Description of the Related Art
[0004] Modern processors commonly use a technique known as pipelining to improve performance. Pipelining is an instruction execution technique that is analogous to an assembly line. Consider that instruction execution often involves the sequential steps of fetching the instruction from memory, decoding the instruction into its respective operation and operand(s), fetching the operands of the instruction, applying the decoded operation on the operands (herein simply referred to as “executing” the instruction), and storing the result back in memory or in a register. Pipelining is a technique wherein the sequential steps of the execution process are overlapped for a sub-sequence of the instructions. For example, while the CPU is storing the results of a first instruction of an instruction sequence, the CPU simultaneously executes the second instruction of the sequence, fetches the operands of the third instruction of the sequence, decodes the fourth instruction of the sequence, and fetches the fifth instruction of the sequence. Pipelining can thus decrease the execution time for a sequence of instructions.
[0005] Another technique for improving performance involves executing two or more instructions in parallel, i.e., simultaneously. Processors that utilize this technique are generally referred to as superscalar processors. Such processors may incorporate an additional technique in which a sequence of instructions may be executed out of order. Results for such instructions must be reassembled upon instruction completion such that the sequential program order or results are maintained. This system is referred to as out of order issue with in-order completion.
[0006] The ability of a superscalar processor to execute two or more instructions simultaneously depends upon the particular instructions being executed. Likewise, the flexibility in issuing or completing instructions out-of-order can depend on the particular instructions to be issued or completed. There are three types of such instruction dependencies, which are referred to as: resource conflicts, procedural dependencies, and data dependencies. Resource conflicts occur when two instructions executing in parallel tend to access the same resource, e.g., the system bus. Data dependencies occur when the completion of a first instruction changes the value stored in a register or memory, which is later accessed by a later completed second instruction.
[0007] During execution of instructions, an instruction sequence may fail to execute properly or to yield the correct results for a number of different reasons. For example, a failure may occur when a certain event or sequence of events occurs in a manner not expected by the designer. Further, an error also may be caused by a misdesigned circuit or logic equation. Due to the complexity of designing an out of order processor, the processor design may logically miss-process one instruction in combination with another instruction, causing an error. In some cases, a selected frequency, voltage, or type of noise may cause an error in execution because of a circuit not behaving as designed. Errors such as these often cause the scheduler in the microprocessor to “hang”, resulting in execution of instructions coming to a halt. A hang may also result due to a “live-lock”—a situation where the instructions may repeatedly attempt to execute, but cannot make forward progress due to a hazard condition. For example, in a simultaneous multi-threaded processor, multiple threads may block each other if there is a resource interdependency that is not properly resolved. Errors do not always cause a “hang”, but may also result in a data integrity problem where the processor produces incorrect results. A data integrity problem is even worse than a “hang” because it may yield an indeterminate and incorrect result for the instruction stream executing.
[0008] These errors can be particularly troublesome when they are missed during simulation and thus find their way onto already manufactured hardware systems. In such cases, large quantities of the defective hardware devices may have already been manufactured, and even worse, may already be in the hands of consumers. For such situations, it was desirable to formulate workarounds which allow such problems to be bypassed so that the defective hardware elements can be used. One such workaround is described in U.S. Pat. No. 6,543,003 to Floyd et al. In accordance with U.S. Pat. No. 6,543,003, the operations of a processor are monitored to detect a hang condition. The detected hang conditions are triggers which trigger the injection of “flush” commands to the processor pipeline which cause the instructions in the execution units to be cleared. The instructions being processed at the time of the trigger are then refetched and reprocessed.
[0009] Having the ability to flush the processor pipeline is an attractive workaround since the flush can clear out the bad state that is detected. Since the flush-and-refetch process can be performed so that it has minimal effect on the overall operation of the processor, it is a very attractive option, even with the potential reduction in processing performance, when compared with the high cost and inconvenience of recovering all of the faulty processors and replacing them.
[0010] To work around specific problematic scenarios that would normally result in an error condition it is desirable to flush the processor pipeline based on a configurable trigger condition based on internal processor events. The use of a configurable trigger in some existing sytems provides the ability to work around problems that do not result in hangs and the ability to detect conditions that would eventually have been resulted in a hang. However, existing mechanisms for introducing configurable trigger based flushes cannot guarantee “forward progress” when performing these flushing operations. A trigger based flush generation may repeatedly cause the flush to repeat each time the flushed instructions are refetched and processed, because the processor may encounter a flush trigger again before the flushed-and-refreshed instructions have had the opportunity to complete execution. This results in an indefinite hang situation, in which the processor essentially loops without progressing forward, which is clearly unacceptable.
[0011] Accordingly, it would be advantageous to have a method and apparatus for bypassing errors in a microprocessor, including those that would cause it to hang or that would result in a loss of data integrity, by flushing the processor pipeline based on a configurable event, while providing a means for safely executing the flushed instructions when they are re-executed and allowing the processor to make forward progress.
SUMMARY OF THE INVENTION
[0012] The present invention allows localized generation of global flush requests while providing a means for increasing the likely hood of forward progress in a controlled fashion. Local hazard (error) detection is accomplished with a trigger network situated between execution units and configurable state machines that track trigger events. Once a hazardous state is detected, a local detection mechanism requests a workaround flush from the flush control logic. The processor is flushed and a centralized workaround control is informed of the workaround flush. The centralized control blocks subsequent workaround flushes until forward progress has been made. The centralized control can also optionally send out a control to activate a set of localized workarounds or reduced performance modes to avoid the hazardous condition once instructions are re-executed after the flush until a configurable amount of forward progress has been made.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a block diagram illustrating a data processing system in which the present invention may be implemented;
[0014] FIG. 2 is a diagram of a portion of a processor core in accordance with a preferred embodiment of the present invention; and
[0015] FIGS. 3 and 4 are flowcharts illustrating the basic operations performed by the flush controller 212 and the workaround controller 218 , respectively of one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] With reference now to FIG. 1 , a block diagram illustrates a data processing system in which the present invention may be implemented. Data processing system 100 is an example of a client computer. Data processing system 100 employs a peripheral component interconnect (PCI) local bus architecture. Although the depicted example employs a PCI bus, other bus architectures such as Accelerated Graphics Port (AGP) and Industry Standard Architecture (ISA) may be used. Processor 102 and main memory 104 are connected to PCI local bus 106 through PCI bridge 108 . PCI bridge 108 also may include an integrated memory controller and cache memory for processor 102 . Additional connections to PCI local bus 106 may be made through direct component interconnection or through add-in boards. In the depicted example, local area network (LAN) adapter 110 , SCSI host bus adapter 112 , and expansion bus interface 114 are connected to PCI local bus 106 by direct component connection. In contrast, audio adapter 116 , graphics adapter 118 , and audio/video adapter 119 are connected to PCI local bus 106 by add-in boards inserted into expansion slots. Expansion bus interface 114 provides a connection for a keyboard and mouse adapter 120 , modem 122 , and additional memory 124 . Small computer system interface (SCSI) host bus adapter 112 provides a connection for hard disk drive 126 , tape drive 128 , and CD-ROM drive 130 . Typical PCI local bus implementations will support three or four PCI expansion slots or add-in connectors.
[0017] An operating system runs on processor 102 and is used to coordinate and provide control of various components within data processing system 100 in FIG. 1 . The operating system may be a commercially available operating system such as AIX, which is available from International Business Machines Corporation. Instructions for the operating system and applications or programs are located on storage devices, such as hard disk drive 126 , and may be loaded into main memory 104 for execution by processor 102 .
[0018] Those of ordinary skill in the art will appreciate that the hardware in FIG. 1 may vary depending on the implementation. Other internal hardware or peripheral devices, such as flash ROM (or equivalent nonvolatile memory) or optical disk drives and the like, may be used in addition to or in place of the hardware depicted in FIG. 1 . Also, the processes of the present invention may be applied to a multiprocessor data processing system.
[0019] For example, data processing system 100 , if optionally configured as a network computer, may not include SCSI host bus adapter 112 , hard disk drive 126 , tape drive 128 , and CD-ROM 130 , as noted by dotted line 132 in FIG. 1 denoting optional inclusion. The data processing system depicted in FIG. 1 may be, for example, an IBM RISC/System 6000 system, a product of International Business Machines Corporation in Armonk, N.Y., running the Advanced Interactive Executive (AIX) operating system.
[0020] The depicted example in FIG. 1 and above-described examples are not meant to imply architectural limitations.
[0021] The present invention provides a method and apparatus for bypassing flaws in a processor, such as (but not limited to) flaws that hang the instruction sequencing or instruction execution within a processor core or that would result in a loss of processor result integrity. The present invention provides a mechanism that allows for localized event or “trigger” monitoring throughout the processor core to initiate the workaround flush within the processor and implements a workaround “safe mode” for a programmable notion of forward progress after the flush (e.g. a number of instruction completions) in an attempt to avoid the design bug detected or warned by the trigger. As is known in the art, when a flush occurs, instructions currently being processed by execution units are cancelled or thrown away. In other words, “flush” means to “cancel” or throw away the effect of the instructions being executed. Then, execution of the instructions is restarted. Flush operations may be implemented by using currently available flush mechanisms for processor cores currently implemented to back out of mispredicted branch paths.
[0022] The mechanism of the present invention may be implemented within processor 102 . With reference next to FIG. 2 , a diagram of a portion of a processor core is depicted in accordance with a preferred embodiment of the present invention. Section 200 illustrates a portion of a processor core for a processor, such as processor 102 in FIG. 1 . Only the components needed to illustrate the present invention are shown in section 200 . Other components are omitted in order to avoid obscuring the invention.
[0023] Referring to FIG. 2 , processor 102 is connected to a memory controller 202 and a memory 204 which may also include a L 2 cache. As is well known, the memory 202 and memory controller 204 function to provide storage, and control access to the storage, for the processor 102 .
[0024] The processor 102 of the present invention includes an instruction cache 206 , and instruction fetcher 208 . An instruction fetcher 208 maintains a program counter and fetches instructions from instruction cache 206 and from more distant memory 204 that may include a L 2 cache. The program counter of instruction fetcher 208 comprises an address of a next instruction to be executed. The L1 cache 206 is located in the processor and contains data and instructions preferably received from an L2 cache in memory 204 . Ideally, as the time approaches for a program instruction to be executed, the instruction is passed with its data, if any, first to the L2 cache, and then as execution time is near imminent, to the L1 cache. Thus, instruction fetcher 208 communicates with a memory controller 202 to initiate a transfer of instructions from a memory 204 to instruction cache 206 . Instruction fetcher 208 retrieves instructions passed to instruction cache 206 and passes them to an instruction dispatch unit 210 .
[0025] Instruction dispatch unit 210 receives and decodes the instructions fetched by instruction fetcher 208 . The dispatch unit 210 may extract information from the instructions used in determination of which execution units must receive the instructions. The instructions and relevant decoded information may be stored in an instruction buffer or queue (not shown) within the dispatch unit 210 . The instruction buffer within dispatch unit 210 may comprise memory locations for a plurality of instructions. The dispatch unit 210 may then use the instruction buffer to assist in reordering instructions for execution. For example, in a multi-threading processor, the instruction buffer may form an instruction queue that is a multiplex of instructions from different threads. Each thread can be selected according to control signals received from control circuitry within dispatch unit 210 or elsewhere within the processor 102 . Thus, if an instruction of one thread becomes stalled, an instruction of a different thread can be placed in the pipeline while the first thread is stalled.
[0026] Dispatch unit 210 dispatches the instruction to execution units ( 214 and 216 ). For purposes of example, but not limitation, only two execution units are shown in FIG. 2 . In a superscalar architecture, execution units ( 214 and 216 ) may comprise load/store units, integer Arithmetic/Logic Units, floating point Arithmetic/Logic Units, and Graphical Logic Units, all operating in parallel. Dispatch unit 210 therefore dispatches instructions to some or all of the executions units to execute the instructions simultaneously. Execution units ( 214 and 216 ) comprise stages to perform steps in the execution of instructions received from dispatch unit 210 . Data processed by execution units ( 214 and 216 ) are storable in and accessible from integer register files and floating point register files not shown. Data stored in these register files can also come from or be transferred to an on-board data cache or an external cache or memory.
[0027] Dispatch unit 210 , and other control circuitry (not shown) include instruction sequencing logic to control the order that instructions are dispatched to execution units ( 214 and 216 ). Such sequencing logic may provide the ability to execute instructions both in order and out-of-order with respect to the sequential instruction stream. Out-of-order execution capability can enhance performance by allowing for younger instructions to be executed while older instructions are stalled.
[0028] Each stage of each of execution units ( 214 and 216 ) is capable of performing a step in the execution of a different instruction. In each cycle of operation of processor 102 , execution of an instruction progresses to the next stage through the processor pipeline within execution units ( 214 and 216 ). Those skilled in the art will recognize that the stages of a processor “pipeline” may include other stages and circuitry not shown in FIG. 2 . In a multi-threading processor, each pipeline stage can process a step in the execution of an instruction of a different thread. Thus, in a first cycle, a particular pipeline stage 1 will perform a first step in the execution of an instruction of a first thread. In a second cycle, next subsequent to the first cycle, a pipeline stage 2 will perform a next step in the execution of the instruction of the first thread. During the second cycle, pipeline stage 1 performs a first step in the execution of an instruction of a second thread. And so forth.
[0029] The program counter of instruction fetcher 208 may normally increment to point to the next sequential instruction to be executed, but in the case of a branch instruction, for example the program counter can be set to point to a branch destination address to obtain the next instruction. In one embodiment, when a branch instruction is received, instruction fetcher 208 predicts whether the branch is taken. If the prediction is that the branch is taken, then instruction fetcher 208 fetches the instruction from the branch target address. If the prediction is that the branch is not taken, then instruction fetcher 208 fetches the next sequential instruction. In either case, instruction fetcher 208 continues to fetch and send to dispatch unit 210 instructions along the instruction path taken. After many cycles, the branch instruction is executed in execution units ( 214 and 216 ) and the correct path is determined. If the wrong branch path was predicted, then flush controller 212 is notified of the mispredicted branch condition. Flush controller 212 then sends control signals to the execution units ( 214 and 216 ), dispatch unit 210 , and instruction fetcher 208 that invalidate instructions from the pipeline that are younger that the branch. Each of the execution units ( 214 and 216 ), dispatch unit 210 , and instruction fetcher 208 have flush handling logic that processes the flush signals from flush controller 212 . In a simultaneous multithreaded processor, the flush logic will distinguish between threads when processing a flush request such the each thread may be flushed individually.
[0030] It can be seen by one skilled in the art how the circuitry required to handle a branch flush, both in the flush controller, and in the processor pipeline may be adapted to flush all instructions as a bug workaround. Thus, in a preferred embodiment, the flush controller 212 and flush logic for each unit may be modified (if necessary) to handle a pipeline flush initiated for such a reason. The flush controller 212 may be a grouping of centralized control circuitry or a distributed control circuitry, whereby multiple elements of flush control logic may reside in physically distant locations but are designed to systematically process flush requests.
[0031] In one embodiment, the workaround flush may be initiated by localized triggering logic distributed throughout the processor core. Trigger logic may reside within instruction fetcher 208 , dispatch unit 210 , execution units ( 214 and 216 ), flush controller 212 and in other locations throughout the core. The triggering logic is designed to have access to local and inter-unit indications of processor state, and uses such state to generate a trigger indication requesting a workaround flush to flush controller 212 . Inter-unit indications of processor state may be passed between units via inter-unit triggering bus 220 . Triggering bus 220 may have a static set of indications from each processor unit, or in a preferred embodiment, may have a configurable set of processor state indications.
[0032] The configuration of triggering logic to generate workaround flush requests and the configuration of the set of processor states available on triggering bus 220 are determined once there is a known hardware error for which a workaround is desired. The triggers can then be programmed to look for the particular workaround scenario. These triggers can be direct or can be event sequences such as A happened before B, or more complex, such as A happened within three cycles of B. Depending on the nature of the error, the triggers may be selected to detect that the error just occurred, or that it may be about to occur.
[0033] An example error condition for which a workaround flush may be desired is the case of an instruction queue overflow within an execution unit ( 214 or 216 ). Continuing with this example, let us consider the case where an instruction queue in execution unit 214 has a design bug that allows a dispatched instruction to be discarded when the queue is full. In such a case, instruction processing results may be lost and the instruction program may yield incorrect results. Upon analysis of the failure mechanism it may be determined that a flush of the instructions in the execution pipeline including those in the instruction queue will clear any bad state from the processor and allow for re-execution of the lost instruction. For this example embodiment, execution unit 214 has an internal “instruction-queue-fill” event available to the local triggering logic. Furthermore, triggering logic of execution unit 214 has access to events from dispatch unit 210 via the inter-unit triggering bus. Furthermore, dispatch unit 210 provides a “dispatch-valid” indication that is active whenever an instruction is dispatched. To activate a trigger and cause a workaround flush of the pipeline when the error condition occurs, the triggering logic of execution unit 214 may be configured to look for an internal “instruction-queue-full” event coincident with a remote “dispatch-valid” event. By configuring the local triggering logic as such, the problem scenario can be detected, and a trigger can be generated and sent to flush controller 212 to cause a flush that will clear up the processor's bad state. One skilled in the art will recognize how unit designers may select events such as “queue-full” and “dispatch-valid” which are likely to be useful in forming triggers for a workaround flush and may make them available to local unit triggering logic and to the inter-unit triggering bus.
[0034] Once a workaround flush request has been made by triggering logic in a processor unit and is received by flush controller 212 , the flush controller 212 will initiate a flush of the processor pipeline for all instructions and notify the workaround controller 218 .
[0035] Workaround controller 218 provides a centralized control for the workaround action and workaround flushing operations being performed by processor 102 . When workaround controller 218 is notified of a workaround flush by flush controller 212 it will immediately send an indication back to flush controller 212 to begin blocking subsequent requests for a workaround flush and may optionally begin to send an indication to the processor units to engage a “safe mode” or back-off mode that will be active by the time the flushed instructions are re-executed. Such a “safe-mode” may be required cases where the flushed instructions would normally re-execute and possible encounter the same error condition that initially triggered the workaround flush.
[0036] In one embodiment, the workaround controller 218 may activate a “safe mode” of operation by sending a trigger via the inter-unit trigger bus 220 . Correspondingly, a processor unit, such as dispatch unit 210 or execution units ( 214 and/or 216 ) may be configured to enter a reduced mode of operation when a trigger is active from workaround controller. In a preferred embodiment, various reduced modes of operation may already be defined in processor 102 and may be engaged either statically or dynamically based on a trigger condition, once a defect is discovered. Use of dynamic modes of engagement for such reduced modes of operation is desirable since these modes may measurably hinder processor performance if statically engaged. Further, such modes may not be successful at avoiding an error condition if engaged dynamically without first flushing the processor. Such is the case when a set of triggers is available to detect when the processor is already in a bad state and may be used to cause a flush, while there may be no set of trigger conditions that can predict when a processor may be about to enter a bad state soon enough to avoid the problem by engaging a workaround. So, an important advantage of the present invention is the ability to react to a configurable state which may already be invalid or problematic, and then cause a flush to clear the erroneous state and subsequently modify the execution mode of the processor such that the error state is avoided.
[0037] Another important advantage of the present invention is the ability to track forward progress through the instruction stream once a workaround flush has occurred and a reduced mode of execution has been engaged such that the reduced mode of execution may be disengaged once the potential problem sequence of instructions that initiated the workaround flush has past. In one embodiment, this is accomplished with the workaround controller 218 . Once the workaround controller 218 detects a workaround flush condition, it also resets a configurable forward progress counter. Such a counter may be implemented with a logical incrementer/decrementer, a linear-feedback-shift-register (LFSR) or any other circuitry that may be used to count events. In a preferred embodiment, the counter can be configured to count various events from the inter-unit trigger bus 220 or a set of statically defined events such as instruction completion. In one embodiment, when an instructions completes the forward progress counter is incremented. Once the counter reaches a configurable limit (such a limit being set based on the nature of the error being bypassed), the workaround controller 218 will disengage the “safe mode” that has been entered, if any, and will re-enable workaround flushes by dropping the blocking indication being sent to the flush controller 212 .
[0038] In one embodiment of the present invention, processor 102 is a simultaneous multithreaded (SMT) processor, and the facilities of the invention are replicated per thread such that independent workaround actions may be taken on each thread independently. Workaround controller 218 may be replicated per thread, or separate facilities may be kept internal to the workaround controller 218 for tracking each thread. In another embodiment, the per thread facilities of the invention are further extended to provide a configurable mode whereby a flush request from a single thread will initiate a workaround flush for all active threads in the processor.
[0039] FIGS. 3 and 4 are flowcharts illustrating the basic operations performed by the flush controller 212 and the workaround controller 218 , respectively of one embodiment of the present invention. Referring first to FIG. 3 , at step 302 , the flush controller 212 monitors workaround flush requests from triggering logic contained within the processors units. If no flush requests have been received, the process reverts back to step 302 and continues to monitor the workaround flush requests from the execution units.
[0040] If, however, at step 304 , a flush request is detected as having been received, at step 306 , a determination is made as to whether or not the flush request has been blocked by the workaround controller 218 . If the flush request has been blocked by the workaround controller 218 , then the process reverts back to step 302 and continues to monitor flush request from the execution units. If, however, at step 306 , it is determined that the flush request was not blocked by the workaround controller 218 , then the process proceeds to step 308 , where the flush indicators are sent to flush the processor pipeline including the execution pipelines, and dispatch controls. An indication that a workaround flush has been initiated is also sent to workaround controller 218 .
[0041] At step 310 , the flush controller 212 waits a predetermined delay period to allow any workaround “safe modes” to be activated by the workaround controller 218 to take effect before refetching the flushed instructions. Once the predetermined delay period has elapsed, at step 312 the flushed instructions are refetched from the instruction fetch unit, and then the process proceeds back to step 302 to continue monitoring workaround flush request from the execution units.
[0042] FIG. 4 is a flow diagram illustrating the basic steps performed by the workaround controller 218 when handling a workaround flush. At step 402 , the workaround controller 218 monitors any workaround flush requests coming from flush controller 212 . If, at step 404 , it is determined that no flush requests have been received, the process reverts back to step 402 to continue the monitoring operation.
[0043] If, however, at step 414 , a flush request is received from the flush controller 212 , the process proceeds to step 406 , and a forward progress counter contained within workaround controller 218 is reset, thereby initializing the counter to begin a new count. The process then proceeds to step 408 , where the workaround controller 218 activates a “block flush” signal and sends it to the flush controller 212 . Additionally, programmable workaround controls for use by the execution units are also activated.
[0044] At step 410 , the workaround controller 218 monitors the forward progress of the processor 102 and its execution units 214 and 216 , and increments the forward progress counter whenever forward progress occurs. At step 412 , determination is made as to whether or not a threshold amount of forward progress (e.g., a the processing of a predetermined number of instructions) has been reached. If the threshold has not been reached, the process proceeds back to step 410 to continue monitoring the forward progress and incrementing the forward progress counter when forward progress occurs. If, at step 412 , is determined that the threshold has been reached, then the process proceeds to step 414 , where the “block flushed” signal to the flush controller is deactivated.
[0045] At step 416 , after waiting long enough to assure that the flushes will be enabled by the time the workaround is deactivated, the process proceeds to step 418 , where the workaround controls are deactivated. The process than proceeds back to step 402 to continue monitoring the workaround flush requests from the flush controller.
[0046] Without the facility of the present invention for disabling workaround flushes during the “safe mode” following a workaround flush, many triggering configurations that might otherwise work, may result in actually introducing a processor hang condition. This may occur if the triggering logic cannot differentiate between cases where an error condition is actually eminent or may be eminent, and cases where the problem will not occur due to the effects of the workaround flush or the effects of “safe modes” engaged after a workaround flush has been initiated. Therefore, even though a workaround flush in conjunction with a post flush “safe mode” may be sufficient to avoid the problem scenario when the flushed instructions are re-executed, the events that trigger the workaround flush may still occur because the events may activate when the processor reaches a state “close” to that of the known error condition, and the workaround “safe mode” that is engaged may not alter these events. Over-indicating a potential problem condition in this way is likely because events available to the triggering logic of each unit may be limited, and it is highly unlikely that all the required events needed to isolate precisely all possible problem scenarios.
[0047] Although the present invention has been described with respect to a specific preferred embodiment thereof, various changes and modifications may be suggested to one skilled in the art and it is intended that the present invention encompass such changes and modifications as fall within the scope of the appended claims. | Localized generation of global flush requests while providing a means for increasing the likelihood of forward progress in a controlled fashion. Local hazard (error) detection is accomplished with a trigger network situated between execution units and configurable state machines that track trigger events. Once a hazardous state is detected, a local detection mechanism requests a workaround flush from the flush control logic. The processor is flushed and a centralized workaround control is informed of the workaround flush. The centralized control blocks subsequent workaround flushes until forward progress has been made. The centralized control can also optionally send out a control to activate a set of localized workarounds or reduced performance modes to avoid the hazardous condition once instructions are re-executed after the flush until a configurable amount of forward progress has been made. | 6 |
The present invention relates to a novel process for preparing (E)-1-amino-2-(fluoromethylene)-4-(p-fluorophenyl)butane, also known in the art as (E)-(p-fluorophenethyl)-3-fluoroallylamine, and pharmaceutically acceptable salts thereof, which are useful as irreversible inhibitors of monoamine oxidase U.S. Pat. No. 4,454,158, Jun. 12, 1984, to novel processes for the preparation of an intermediate thereof, and to novel intermediates useful in the preparation of (E)-1-amino-2-(fluoromethylene)-4-(p-fluorophenyl)butane.
BACKGROUND OF THE INVENTION
A general process for preparing allyl amines including (E)-1-amino-2-(fluoromethylene)-4-(p-fluorophenyl)butane is described in U.S. Pat. No. 4,454,158, issued Jun. 12, 1984. A process for preparing (E)-1-amino-2-(fluoromethylene)-4-(p-fluorophenyl)butane is described in International Application No. WO 93/24120, (PCT) published Dec. 9, 1993 and European Pat. Application No. 0 295 604, published Dec. 21, 1988.
These methods, however, have the disadvantage that some of the steps to prepare a useful intermediate, (E)-2-(fluoromethylene)- 4-(p-fluorophenyl)butan-1-ol, use reagents and conditions that do not allow for economical, large scale, production of (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butan-1-ol. Further, these methods use a phthalimide containing intermediate, the removal of which gives (E)-1-amino-2-(fluoromethylene)-4-(p-fluorophenyl)butane contaminated with phthalhydrazide which is difficult to remove from the final product.
The process of the present invention for preparing (E)-1-amino-2-(fluoromethylene)-4-(p-fluorophenyl)butane utilizes alkali metal salts of diformylamide. Generally, these salts are only partially soluble in useful solvents which causes the reaction rate to be surface area dependent.
The preparation and use of alkali metal salts of diformylamide is known in the art. J. N. Rakshit, J. Chem. Soc., 103, 1557-1562 (1913); E. Allenstein and V. Beyl, Chem. Ber. 100, 3551-3563 (1967); H. Yinglin and H. Hongwen, Synthesis 7, 122-124 (1990); and H. Yinglin and H. Hongwen, Synthesis 7, 615-618 (1990).
The methods for preparing alkali metal salts of diformylamide, however, have the disadvantage that the material is obtained as a solid mass. The solid obtained must be broken up which leads to material of differing and irregular particle size. Moreover, milling alkali metal salts of diformylamide to increase the surface area creates dust and inhalation problems. Further, the method of E. Allenstein and V. Beyl for preparing alkali metal salts of diformylamide, when carried out on large scale, gives material that is contaminated with detrimental amounts of methanol and ammonia.
An object of the present invention, therefore, is to provide novel methods for the economical preparation of (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butan-1-ol which can be carried out without purification between steps.
Another object of the present invention is to provide a novel method for producing (E)-1-amino-2-(fluoromethylene)-4-(p-fluorophenyl)butane utilizing intermediates which provide the final product without difficult to remove by-products.
Another object of the present invention is to provide a novel process for crystallizing alkali metal salts of diformylamide that gives alkali metal salts of diformylamide as a free flowing granular solid that is free of detrimental amounts of methanol and ammonia.
A further object of the present invention is to provide novel intermediates useful for preparing (E)-1-amino-2-(fluoromethylene)-4-(p-fluorophenyl)butane.
SUMMARY OF THE INVENTION
The present invention provides a novel process for preparing (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butan-1-ol comprising the steps of:
a) reacting 4-(p-fluorophenyl)butyric acid with isobutylene to give t-butyl 4-(p-fluorophenyl)butyrate;
b) reacting t-butyl 4-(p-fluorophenyl)butyrate with an appropriate alkyl chloroformate to give an alkyl 2-(t-butoxycarbonyl)-4-(p-fluorophenyl)butyrate;
c) reacting an alkyl 2-(t-butoxycarbonyl)-4-(p-fluorophenyl)butyrate with an appropriate difluoromethane transfer reagent to give an alkyl 2-(difluoromethyl)-2-t-butoxycarbonyl-4-(p-fluorophenyl)butyrate:
d) reacting an alkyl 2-(difluoromethyl)-2-(t-butoxycarbonyl)-4-(p-fluorophenyl)butyrate with an appropriate acid to give an alkyl 2-(difluoromethyl)-2-carboxy-4-(p-fluorophenyl)butyrate;
e) reacting an alkyl 2-(difluoromethyl)-2-carboxy-4-(p-fluorophenyl)butyrate with an appropriate base to give an alkyl (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butyrate;
f) reacting an alkyl (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butyrate with an appropriate reducing agent.
Furhter, the present invention provides a novel process for preparing (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butan-1-ol comprising the steps of:
a) reacting 4-(p-fluorophenyl)butyric acid with isobutylene to give t-butyl 4-(p-fluorophenyl)butyrate;
b) reacting t-butyl 4-(p-fluorophenyl)butyrate with an appropriate alkyl chloroformate to give a reaction mixture and then reacting the reaction mixture with an appropriate difluoromethane transfer reagent to give an alkyl 2-(difluoromethyl)-2-(t-butoxycarbonyl)-4-(p-fluorophenyl)butyrate;
c) reacting an alkyl 2-(difluoromethyl)-2-(t-butoxycarbonyl)-4-(p-fluorophenyl)butyrate with an appropriate acid to give an alkyl 2-(difluoromethyl)-2-carboxy-4-(p-fluorophenyl)butyrate;
d) reacting an alkyl 2-(difluoromethyl)-2-carboxy-4-(p-fluorophenyl)butyrate with an appropriate base to give an alkyl (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butyrate;
e) reacting an alkyl (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butyrate with an appropriate reducing agent.
In addition, the present invention provides a novel process for preparing (E)-1-amino-2-(fluoromethylene)-4-(p-fluorophenyl)butane and pharmaceutically acceptable salts thereof comprising the steps of:
a) reacting (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butan-1-ol with an appropriate halogenating agent to give a (E)-1-halo-2-(fluoromethylene)-4-(p-fluorophenyl)butane;
b) reacting a (E)-1-halo-2-(fluoromethylene)-4-(p-fluorophenyl)butane with an alkali metal salt of diformylamide to give (E)-N-(2-(fluoromethylene)-4-(p-fluorophenyl)butyl)-N-formyl formamide;
c) reacting (E)-N-(2-(fluoromethylene)-4-(p-fluorophenyl)butyl)-N-formyl formamide with an appropriate hydrolysis agent.
In addition, the present invention provides a novel process for crystallizing alkali metal salts of diformylamide comprising the steps of:
a) dissolving an alkali metal salt of diformylamide in a hydroxylic solvent;
b) distilling the hydroxylic solvent while adding an anti-solvent.
In addition, the present invention provides for novel compounds of the formula: ##STR1## wherein X is chloro, bromo or--N(CHO) 2 .
DETAILED DESCRIPTION OF THE INVENTION
As used in this application:
a) the term "--N(CHO) 2 " refers to a radical of the formula; ##STR2## b) the term "halo" refers to a chlorine atom, a bromine atom, or an iodine atom;
c) the term "pharmaceutically acceptable salts" refers to acid addition salts.
The expression "pharmaceutically acceptable acid addition salts" is intended to apply to any non-toxic organic or inorganic acid addition salt of (E)-1-amino-2-(fluoromethylene)-4-(p-fluorophenyl)butane. Illustrative inorganic acids which form suitable salts include hydrochloric, hydrobromic, sulphuric, and phosphoric acid and acid metal salts such as sodium monohydrogen orthophosphate, and potassium hydrogen sulfate. Illustrative organic acids which form suitable salts include the mono-, di-, and tricarboxylic acids. Illustrative of such acids are for example, acetic, glycolic, lactic, pyruvic, malonic, succinic, glutaric, fumaric, malic, tartaric, citric, ascorbic, maleic, hydroxymaleic, benzoic, hydroxybenzoic, phenylacetic, cinnamic, salicylic, 2-phenoxybenzoic, and sulfonic acids such as p-toluenesulfonic acid, methanesulfonic acid and 2-hydroxyethanesulfonic acid. Such salts can exist in either a hydrated or substantially anhydrous form.
Examples of compounds encompassed by the present invention include:
(E)-1-chloro-2-(fluoromethylene)-4-(p-fluorophenyl)butane;
(E)-1-bromo-2-(fluoromethylene)-4-(p-fluorophenyl)butane;
(E)-N-(2-(fluoromethylene)-4-(p-fluorophenyl)butyl)-N-formyl formamide.
A general synthetic procedure is set forth in Scheme A. In Scheme A, all substituents unless otherwise indicated, are as previously defined. Reagents, techniques, and procedures used in Scheme A are well known and appreciated by one of ordinary skill in the art. ##STR3##
In Scheme A, step 1, 4-(p-fluorophenyl)butyric acid is contacted with isobutylene to give t-butyl 4-(p-fluorophenyl)butyrate.
For example, 4-(p-fluorophenyl)butyric acid is contacted with isobutylene. The reaction is carried out using 5% to 15% by weight of a strong acid catalyst, such as sulfuric acid, with 8% to 12% being preferred and 10% being most preferred. The reaction is tolerant of some water in the starting material with the use of 4-(p-fluorophenyl)butyric acid containing less than 5% by weight water being preferred. The reaction is carried out in isobutylene without a solvent. The reaction is carried out using 1 to about 5 molar equivalents of isobutylene, with 2 to 4 molar equivalents being preferred and 3 molar equivalents being most preferred. The reaction can be carried out by combining 4-(p-fluorophenyl)butyric acid and a strong acid catalyst and either adding the resulting mixture to isobutylene or preferably adding isobutylene to the resulting mixture. Regardless of the order of addition, cooling is required to control the exotherm that occurs during mixing. When isobutylene is added to a 4-(p-fluorophenyl)butyric acid/sulfuric acid mixture, the mixture is cooled to a temperature of between -30° C. and 0° C. before the addition of isobutylene, with -20° C. and -10° C. being preferred. The reaction is carried out at a temperature of from about 0° C. to about 40° C, with 10° C. to 30° C. being preferred and 20° C. to 25° C. being most preferred. The reaction generally requires from 3 to 12 hours. The product is obtained by quenching with a suitable base, such as sodium hydroxide or potassium hydroxide, in the presence of isobutylene. The quench is carried out at a temperature of from about -5° C. to about 5° C. The product can be used after isolation by methods well known and appreciated in the art, such as extraction and evaporation. The product can be purified by methods well known and appreciated in the art, such as distillation.
In Scheme A, step 2, t-butyl 4-(p-fluorophenyl)butyrate is contacted with an appropriate alkyl chloroformate to give an alkyl 2-(t-butoxycarbonyl)-4-(p-fluorophenyl)butyrate.
An appropriate alkyl chloroformate is one which transfers an alkoxy carbonyl group which allows for selective removal of the t-butyl ester, does not interfere with the difluoromethylation step or the decarboxylative elimination step and can be subsequently reduced to give a hydroxymethyl group. Examples of an appropriate alkyl chloroformate include methyl chloroformate, ethyl chloroformate, propyl chloroformate, butyl chloroformate, isobutyl chloroformate, and the like, with ethyl chloroformate being preferred.
For example, t-butyl 4-(p-fluorophenyl)butyrate is contacted with an appropriate alkyl chloroformate. The reaction is carried out in a suitable solvent such as tetrahydrofuran, or toluene/tetrahydrofuran mixtures. The reaction is carried out using from about 1 to about 2 molar equivalents of a suitable base. A suitable base is non-nucleophilic and is of sufficient strength to remove a proton from the methylene moiety adjacent to the carboxy group of the starting ester. Suitable bases are known in the art, and include sodium hydride, sodium bis(trimethylsilyl)amide, lithium diisopropylamide, and the like. The reaction is carried out at a temperature of from about -78° C. to about 0° C., with -20° C. 0° C. to being preferred. The formation of by-products is minimized by the addition of t-butyl 4-(p-fluorophenyl)butyrate to a solution of a suitable base followed by addition of an appropriate alkyl chloroformate. The product can be isolated by methods well known and appreciated in the art, such as extraction and evaporation. The product can be purified by methods well known and appreciated in the art, such as chromatography and distillation.
In Scheme A, step 3, an alkyl 2-(t-butoxycarbonyl)-4-(p-fluorophenyl)butyrate is contacted with an appropriate difluoromethane transfer reagent to give an alkyl 2-(difluoromethyl)-2-(t-butoxycarbonyl)-4-(p-fluorophenyl)butyrate.
An appropriate difluoromethane transfer reagent is one that transfers a difluoromethyl group under the conditions of the reaction. Examples of an appropriate difluoromethane transfer reagent include chlorodifluoromethane, bromodifluoromethane, and the like.
For example, an alkyl 2-(t-butoxycarbonyl)-4-(p-fluorophenyl)butyrate is contacted with from 1.25 to 1.4 molar equivalents of an appropriate difluoromethane transfer reagent. The reaction is carried out in a suitable solvent, such as tetrahydrofuran, or toluene/tetrahydrofuran mixtures. The reaction is carried out using a suitable base. A suitable base is non-nucleophilic and is of sufficient strength to remove a proton from the methine moiety adjacent to the carboxy groups of the starting diester. Suitable bases having a sodium counter ion being preferred. Suitable bases are known in the art, and include sodium hydride, sodium t-butoxide and sodium bis(trimethylsilyl)amide, with sodium bis(trimethylsilyl)amide being preferred and sodium bis(trimethylsilyl)amide having a titration value of 2.1 or less being most preferred. The reaction is carried out at a temperature of from about 20° C. to about 50° C., with 40° C. to 45° C. being preferred. The reaction generally requires 30 minutes to 2 hours. The product is obtained by quenching using a suitable acid, such as acetic acid. The quench is carried out at a temperature of from about 15° C. to about 25° C. The product can be isolated by extraction and used as a solution without purification or the product can be obtained as a solution in another solvent by exchanging solvents by evaporation, as is well known in the art. The product can be isolated and purified by methods well known and appreciated in the art, such as extraction, evaporation, and distillation.
In Scheme A, step 2 and step 3 can be carried out without isolating the compound of structure (3) formed in step 2, thus, a t-butyl 4-(p-fluorophenyl)butyrate is contacted with an appropriate alkyl chloroformate to give a reaction mixture and then the reaction mixture is contacted with an appropriate difluoromethane transfer reagent to give an alkyl 2-(difluoromethyl)-2-(t-butoxycarbonyl)-4-(p-fluorophenyl)butyrate.
An appropriate alkyl chloroformate is as defined in Scheme A, step 2, and an appropriate difluoromethane transfer reagent is as defined in Scheme A, step 3.
For example, t-butyl 4-(p-fluorophenyl)butyrate is contacted with an appropriate alkyl chloroformate. The reaction is carried out in a suitable solvent such as tetrahydrofuran, or toluene/tetrahydrofuran mixtures. The reaction is carried out using from about 2 to about 3 molar equivalents of a suitable base. A suitable base is non-nucleophilic and is of sufficient strength to remove a proton from the methylene moiety adjacent to the carboxy group of the starting ester. Suitable bases having a sodium counter ion being preferred. Suitable bases are known in the art, and include sodium hydride, sodium t-butoxide and sodium bis(trimethylsilyl)amide, with sodium bis(trimethylsilyl)amide being preferred and sodium bis(trimethylsilyl)amide having a titration value of 2.1 or less being most preferred. The reaction with an appropriate alkyl chloroformate is carried out at a temperature of from about -70° C. to about 0° C., with -20° C. to 0° C. being preferred. The formation of by-products is minimized by the addition of t-butyl 4-(p-fluorophenyl)butyrate to a solution of a suitable base followed by addition of an appropriate alkyl chloroformate.
After a time, generally, 10 minutes to 3 hours, a reaction mixture is obtained which comprises a substantial amount of an alkyl 2-(t-butoxycarbonyl)-4-(p-fluorophenyl)butyrate, along with the selected suitable base, as a solution in the selected suitable solvent. The reaction mixture is warmed to a temperature of from about 20° C. to about 50° C., with 40° C. to 45° C. being preferred. The reaction mixture is then contacted with from 1.25 to 1.4 molar equivalents of an appropriate difluoromethane transfer reagent. Generally, the reaction with an appropriate difluoromethane transfer reagent requires 30 minutes to 2 hours. The product is obtained by quenching using a suitable acid, such as acetic acid. The quench is carried out at a temperature of from about 15° C. to about 25° C. The product can be isolated by extraction and used as a solution without purification or the product can be obtained as a solution in another solvent by exchanging solvents by evaporation, as is well known in the art. The product can be isolated and purified by methods well known and appreciated in the art, such as extraction, evaporation, and distillation.
In Scheme A, step 4, an alkyl 2-(difluoromethyl)-2-(t-butoxycarbonyl)-4-(p-fluorophenyl)butyrate with an appropriate acid to give an alkyl 2-(difluoromethyl)-2-carboxy-4-(p-fluorophenyl)butyrate.
For example, an alkyl 2-(difluoromethyl)-2-(t-butoxycarbonyl)-4-(p-fluorophenyl)butyrate is contacted with 5% to 30% by weight of an appropriate acid. An appropriate acid is an organic or inorganic acid which serves as a catalyst for the removal of a t-butyl ester but does not cause the formation of detrimental by-products. Examples of an appropriate acid include trifluoroacetic acid, methanesulfonic acid, sulfuric acid, hydrochloric acid, formic acid and the like, with methanesulfonic acid and trifluoroacetic acid being preferred and methanesulfonic acid being most preferred. The reaction is carried out either without a solvent or with a suitable solvent, such as toluene, tetrahydrofuran, or toluene/tetrahydrofuran mixtures. The use of a solvent is preferred. When a solvent is used, toluene is preferred. The reaction is carried out at a temperature of from about 20° C. to about 60° C., with 40° C. to 50° C. being preferred. The product can be isolated by extraction to give the product as a solution. The product can be purified by techniques well known in the art, such as evaporation, and recrystallization. The product can also be extracted into water using an appropriate base and used as an aqueous solution of its salt in the next step without purification.
In Scheme A, step 5, an alkyl 2-(difluoromethyl)-2-carboxy-4-(p-fluorophenyl)butyrate is contacted with an appropriate base to give an alkyl (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butyrate.
An appropriate base is any base capable of removing the carboxy proton of an alkyl 2-(difluoromethyl)-2-carboxy-4-(p-fluorophenyl)butyrate in a decarboxylative elimination reaction to give (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butyrate. Appropriate bases include triethylamine, sodium bicarbonate, sodium carbonate, sodium hydroxide, potassium hydroxide, and the like.
For example, an alkyl 2-(difluoromethyl)-2-carboxy-4-(p-fluorophenyl)butyrate is contacted with an essentially equimolar amount of an appropriate base. The reaction is carried out in a suitable solvent, such as tetrahydrofuran, toluene, water or tetrahydrofuran/water mixtures with tetrahydrofuran/water mixtures being preferred and tetrahydrofuran/water mixtures of around 1 to 1 by weight being most preferred. The reaction is carried out at a temperature of from about -10° C. to about 40° C., with 0° C. to 25° C. being preferred. The reaction generally requires from 1 to 6 hours. The product can be isolated by techniques well known in the art, such as extraction and evaporation. The product can also be purified by techniques well known in the art, such as chromatography and distillation.
In Scheme A, step 6, an alkyl (E)-2-(fluoromethylene)4-(p-fluorophenyl)butyrate is contacted with an appropriate reducing agent to give (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butan-1-ol.
An appropriate reducing agent is one that is capable of reducing the ester group of an alkyl (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butyrate in the presence of the fluoromethylene group. Appropriate reducing agents include sodium borohydride, lithium borohydride, potassium tri-sec-butylborohydride, 9-borabicyclo[3.3.1]nonane, lithium aluminum hydride, diisobutylaluminum hydride, and the like, with diisobutylaluminum hydride being preferred.
For example, an alkyl (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butyrate is contacted with about 2.0 to about 3.0 equivalents of an appropriate reducing agent. The reaction is carried out in a suitable solvent, such as hexane, cyclohexane, dichloromethane, tetrahydrofuran, or toluene, with tetrahydrofuran and toluene being preferred and toluene being most preferred. The reaction is carried out by either adding a solution of an alkyl (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butyrate to a solution of an appropriate reducing agent or adding a solution of an appropriate reducing agent to a solution of an alkyl (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butyrate. The addition is carried out at a temperature of from about -30° C. to about 10° C. The reaction is carried out at a temperature of from about 0° C. to about 30° C. The reaction generally requires 2 to 5 hours. The product can be isolated by quenching and extraction. The quench is carried out at a temperature of from about -15° C. to about 0° C. The product can be isolated as a solution by methods well known and appreciated in the art, such as extraction and evaporation. The product can be purified as is well known in the art by chromatography and distillation.
In Scheme A, step 7, (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butan-1-ol is contacted with an appropriate halogenating agent to give a (E)-1-halo-2-(fluoromethylene)-4-(p-fluorophenyl)butane.
An appropriate halogenating agent is one that converts a hydroxyl group to a halo group and does not cause the degradation of the the starting material or the product. Appropriate halogenating reagents are well known in the art and include, phosphorous trichloride, phosphorous tribromide, thionyl chloride, thionyl bromide, oxalyl chloride, the Vilsmeier reagent, and the like. As is well known in the art, the Vilsmeier reagent can be formed utilizing either a catalytic amount or slight molar excess of N,N-dimethylformamide and various chlorinating agents, such as phosphoryl chloride, phosgene, phosphorous trichloride, and oxalyl chloride.
For example, (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butan-1-ol is contacted with 1.0 to 1.5 molar equivalents of an appropriate halogenating agent. The reaction is carried out in a suitable solvent, such as dichloromethane and toluene. The reaction is carried out at a temperature of from about 20° C. to about 30° C. The reaction generally requires 4 to 24 hours. The product can be isolated by quenching with aqueous sodium chloride solution, extraction, and evaporation. The product can be purified as is well known in the art by chromatography and distillation.
In Scheme A, step 8, a (E)-1-halo-2-(fluoromethylene)4-(p-fluorophenyl)butane is contacted with an alkali metal salt of diformylamide to give (E)-N-(2-(fluoromethylene)-4-(p-fluorophenyl)butyl)-N-formyl formamide.
Examples of an alkali metal salt of diformylamide, include sodium diformylamide, potassium diformylamide, and the like.
For example, a (E)-1-halo-2-(fluoromethylene)-4-(p-fluorophenyl)butane is contacted with 1.0 to 1.6 molar equivalents of an alkali metal salt of diformylamide. The reaction may be carried out in the presence of 0.05 to 0.5 molar equivalents of a suitable catalyst, such as sodium iodide or potassium iodide. The reaction is carried out in a suitable solvent, such as N-methylpyrrolidinone, N,N-dimethylformamide, acetonitrile, N-methylpyrrolidinone/acetonitrile mixtures, N,N-dimethylformamide/acetonitrile mixtures, or N,N-dimethylformamide/acetonitrile/toluene mixtures. The reaction is carried out at a temperature of from about 50° C. to about 90° C. The reaction generally requires 2 to 24 hours. The product can be isolated by quenching and extraction. The product can be purified as is well known in the art by chromatography and recrystallization.
In Scheme A, step 9, (E)-N-(2-(fluoromethylene)-4-(p-fluorophenyl)butyl)-N-formyl formamide is contacted with an appropriate hydrolysis agent to give (E)-1-amino-(2-fluoromethylene)-4-(p-fluorophenyl)butane.
Appropriate hydrolysis agents are well known in the art including alkali metal hydroxides, such as lithium hydroxide, sodium hydroxide, potassium hydroxide and the like, and aqueous solutions of acids, such as hydrochloric acid, hydrobromic acid, and the like. For example, (E)-N-(2-(fluoromethylene)-4-(P-fluorophenyl)butyl)-N-formyl formamide is contacted with an appropriate hydrolysis agent. The reaction is carried out in a suitable solvent, such as water, methanol, ethanol, methanol/water mixtures, ethanol/water mixtures, and tetrahydrofuran/water mixtures. The reaction is carried out at a temperature of from about 0° C. to about 150° C. The reaction generally requires 2 to 24 hours. The product can be isolated by quenching and extraction. The product can be purified as is well known in the art by chromatography and recrystallization.
In Scheme A, optional step 10, (E)-1-amino-2-(fluoromethylene)-4-(p-fluorophenyl)butane is contacted, as is well known in the art, with an appropriate pharmaceutically acceptable acid to form a pharmaceutically acceptable acid addition salt.
Alkali metal salts of diformylamide, such as lithium diformylamide, sodium diformylamide, and potassium diformylamide are obtained as a granular solid by a novel crystallization process comprising the steps of: dissolving an alkali metal salt of diformylamide in a hydroxylic solvent and removing the hydroxylic solvent by distillation while adding an anti-solvent.
For example, an alkali metal salt of diformylamide is dissolved in a hydroxylic solvent, such as methanol, ethanol, propanol, isopropanol, butanol, and the like, with methanol being preferred. The volume of hydroxylic solvent used is not critical but should be kept to a minimal amount as a matter of convenience. The solution is heated to the temperature at which the hydroxylic solvent begins to distill and an anti-solvent is added to replace the hydroxylic solvent lost upon distillation. Examples of an anti-solvent include benzene, chlorobenzene, toluene, xylene, cyclohexane, hexane, cyclopentane, heptane, octane, isooctane, dichloromethane, acetonitrile, ethyl acetate, acetone, butanone, and tetrachloroethylene, with benzene, toluene, cyclohexane, and acetonitrile being preferred and toluene being most preferred. Distillation is continued until the alkali metal salt of diformylamide crystallizes. The volume of the solution being decreased as necessary to facilitate crystallization. The distillation may be continue until the hydroxylic solvent is substantially removed. The alkali metal salt of diformylamide is isolated by filtration and dried.
The foregoing processes are exemplified by the procedures given below. These procedures are understood to be illustrative only and are not intended to limit the scope of the invention in any way. As used in the procedures, the following terms have the meanings indicated: "g" refers to grams; "kg" refers to kilograms; "mol" refers to moles; "mmol" refers to millimoles; "mL" refers to milliliters; "L" refers to liters; "bp" refers to boiling point; "mp" refers to melting point; "lb" refers to pounds; "° C." refers to degrees Celsius; "dec" refers to decomposition; "M" refers to molar; "psi" refers to pounds per square inch.
Preparation of (E)-2-(fluoromethylene)-4-p-fluorophenyl)butan-1-ol
1.1 Synthesis of t-butyl 4-(p-fluorophenyl)butyrate
Scheme A, step 1: ##STR4##
Combine 4-(p-fluorophenyl)butyric acid (51.4 g) and sulfuric acid (5.28 g, 98% Reagent ACS) in a Fisher-Porter bottle. Cool with a dry-ice bath to an internal temperature of between 0° C. and -20° C. Add isobutylene (54 g). Warm to ambient temperature. After 3 hours, cool in a dry-ice/acetone bath until the internal pressure differential of the vessel was 0 psi or less (about -20° C.). Carefully vent the Fisher-Porter bottle and add a cold solution of 5 M sodium hydroxide (51.5 g). Reseal the Fisher-Porter bottle and allow to warm to ambient temperature with vigorous stirring. Vent the Fisher-Porter vessel to remove excess isobutylene. Extract the reaction mixture with toluene (75 g). Separate the organic layer and extract with a saturated sodium bicarbonate solution (77 g). Evaporate in vacuo to obtain the title compound. 1 H NMR (CDCl 3 , 300 MHz) δ1.45 (s, 9H), 1.84 (m, 2H) 2.23 (t, J=7.5 Hz, 2H), 2.61 (t, J=7.5 Hz, 2H), 6.96 (m, 2H), 7.13 (m, 2H).
2.1 Synthesis of ethyl 2-(t-butoxycarbonyl)-4-(P-fluorophenyl)butyrate
Scheme A, step 2: ##STR5##
Prepare a solution of lithium diisopropylamide from diisopropylamine (22.74 g) and 1.6M n-butyl lithium (143.7 mL) in tetrahydrofuran (200 mL). Cool to -78° C. Slowly add t-butyl 4-p-(fluorophenyl)butyrate (26.76 g) as a solution in tetrahydrofuran (100 mL). After 1 hour, add ethyl chloroformate (12.19 g) as a solution in tetrahydrofuran (100 mL). After 24 hours, pour the reaction mixture into water, neutralize with dilute aqueous hydrochloric acid solution. Extract with diethyl ether. Dry the organic layer over MgSO 4 , filter, and evaporate in vacuo to give the title compound.
3.1 Synthesis of ethyl 2-(difluoromethyl)-2-(t-butoxycarbonyl)-4-(p-fluorophenyl)butyrate
Scheme A, step 3: ##STR6##
Combine ethyl 2-(t-butoxycarbonyl)-4-(p-fluorophenyl)butyrate (32.14 g) and sodium t-butoxide (19.81 g) in tetrahydrofuran (400 mL). Stir the mixture for 1 hour, then heat to 45° C. Add an excess of chlorodifluoromethane over about 15 minutes. After 1 hour under an atmosphere of chlorodifluoromethane, allow the temperature to fall to ambient. Pour the reaction mixture into water/brine. Extract with diethyl ether. Dry the organic layer over MgSO 4 , filter, and evaporate in vacuo to give the title compound.
3.2 Synthesis of ethyl 2-(difluoromethyl),2-(t-butoxycarbonyl)-4-(p-fluorophenyl)butyrate
Scheme A, step 2 and Scheme A, step 3:
Cool a tetrahydrofuran solution of sodium bis(trimethylsilyl)amide (545 kg, 2M, 877 mol) to -10° C. Slowly add, t-butyl 4-(p-fluorophenyl)butyrate (84.1 kg, 80% by weight in toluene, 353 mol). After 15 minutes, slowly add ethyl chloroformate (38.6 kg, 356 mol) at such a rate that the reaction temperature is maintained at or below -5° C. After 20 minutes, warm the reaction mixture to 40° C.-45° C. Seal the reaction vessel and add chlorodifluoromethane (38.15 kg, 445 mol) to the head space. After 1 hour, cool to 15° C. -20° C. and vent the reaction vessel. Add a solution of acetic acid (421 kg, 20% in water) and stir. After 30 minutes, separate the aqueous layer and evaporate the organic layer in vacuo to obtain a residue. Add toluene (45 kg) and evaporate in vacuo until the internal temperature of the reaction vessel is 55° C. to obtain the title compound as a toluene solution.
4.1 Synthesis of ethyl 2-(difluoromethyl)-2-carboxy-4-(P-fluorophenyl)butyrate
Scheme A, step 4: ##STR7##
Add methanesulfonic acid (47.7 kg, 496 mol) to a toluene solution of ethyl 2-(difluoromethyl)-2-(t-butoxycarbonyl)-4-(p-fluorophenyl)butyrate as prepared in Example 3.1 at a temperature of 40° C. 50° C. After 3 to 6 hours, cool the reaction to ambient temperature. Add toluene (91 kg) and water (421 kg) and stir for 30 minutes. Separate the aqueous layer. Add to the organic layer a 20% by weight solution of sodium chloride in water (420 kg) and stir for 30 minutes. Separate the layers to give the title compound as a solution in toluene.
5.1 Synthesis of ethyl (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butyrate
Scheme A, step 5: ##STR8##
Cool to 0° C.-10° C. a toluene solution of ethyl 2-(difluoromethyl)-2-carboxy-4-(p-fluorophenyl)butyrate as prepared in Example 4.1. Add water (396 kg) and a 50% by weight aqueous solution of sodium hydroxide. Stir for 30 minutes. Separate the aqueous layer and cool the aqueous layer to 0° C.-5° C. Add tetrahydrofuran (421 kg). Stir for 1 hour at 0° C. and then warm to 25° C. and stir for 3 hours. Separate the aqueous layer. Evaporate the organic layer in vacuo at a temperature of 40° C.-50° C. The evaporation is continued until tetrahydrofuran no longer comes over and then toluene is added. Evaporate in vacuo until there is no longer water visible in the condensate. Concentrate in vacuo to give the title compound as a 80-90% by weight solution in toluene. An analytical sample prepared by evaporation of solvent gave 1 H NMR (CDCl 3 , 300 MHz) δ1.28 (t, J=7.2 Hz 3H), 2.58 (m, 2H), 2.71 (m, 2H) 4.21 (q, J=7.2 Hz, 2H), 6.93 (m, 2H), 7.15 (m, 2H), 7.51 (d, J=81.9 Hz, 1H).
6.1 Synthesis of (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butan-1-ol
Scheme A, step 6: ##STR9##
Combine ethyl (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butyrate (1.5 g, 6.24 mmol) and toluene (5 mL). Cool to -15° C. Add dropwise, a solution of diisobutylaluminum hydride (10.4 mL, 1.5M in toluene, 15.6 mmol). Warm to ambient temperature. After 18 hours, cool to 0° C. With vigorous stirring add sequentially, methanol (15 mL), an aqueous 5M hydrochloric acid solution (25 mL), and water (35 mL). When gas evolution ceases, extract with toluene. Separate the layers and evaporate organic layer in vacuo to give the title compound. 1 H NMR (CDCl 3 , 300 MHz) δ2.28 (s, 1H), 2.45 (m, 2H), 2.72 (m, 2H) 3.91 (d, J=3 Hz, 2H), 6.57 (d, J=87 Hz, 1H), 6.96 (m, 2H), 7.13 (m, 2H).
6.2 Synthesis of (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butan-1-ol
Scheme A, step 6:
Cool to 0° C. a solution of diisobutylaluminum hydride (7.64 kg, 25% by weight in toluene, 13.42 mol). Add a solution of ethyl (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butyrate (1.74 kg, 74.1% by weight in toluene, 5.37 mol) at such a rate that the temperature of the reaction mixture does not rise above 20° C. After the addition is complete, warm to ambient temperature. After 2 hours, cool to 0° C. Slowly, add methanol (7.73 kg) at such a rate that the temperature of the reaction mixture does not rise above 15° C. Cool to 0° C. Slowly, add water (7.96 kg) at such a rate that the temperature of the reaction mixture does not rise above 20° C. Add a concentrated aqueous solution of hydrochloric acid (7.59 kg). Warm to ambient temperature. Separate the organic layer and dry azeotropically by distillation in vacuo until the volume of the organic layer is about one half of its original volume to give the title compound as a solution in toluene.
Preparation of (E)-1-amino-2-(fluoromethylene)-4-(p-fluorophenyl)butane
7.1 Synthesis of (E)-1-bromo-2-(fluoromethylene)-4-(p-fluorophenyl)butane
Scheme A, step 7: ##STR10##
Combine (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butan1-ol (4.0 g, 20.2 mmol) and toluene (10 mL). Cool to about -5° C. Add dropwise, a solution of phosphorous tribromide (1.8 g, 6.65 mmol) in toluene (5 mL). After 1 hour, warm to ambient temperature. After 18 hours, cool to 0° C. and then add saturated sodium bicarbonate solution (50 mL). Separate the layers and extract the aqueous layer 3 times with toluene (40 mL). Extract the combined organic layers with a saturated aqueous sodium chloride solution, dry over Na 2 SO 4 , filter, and evaporate in vacuo to give the title compound.
7.2.1 Synthesis of (E)-1-chloro-2-(fluoromethylene)-4-(p-fluorophenyl)butane
Scheme A, step 7: ##STR11##
Combine oxalyl chloride (2.71 g, 21.4 mmol) and toluene (20 mL). Cool to 0° C. Add N,N-dimethylformamide (1.62 g, 22.2 mmol) as a solution in toluene (2 mL). Warm to ambient temperature. After 10 minutes, cool to 0° C. Add (E)-2(fluoromethylene)-4-(p-fluorophenyl)butan-1-ol (4.0 g, 20.2 mmol) Warm to ambient temperature. After 18 hours, pour the reaction mixture into a saturated sodium chloride solution (100 mL). Extract the aqueous layer 3 times with toluene. Dry the combined organic layers over Na 2 SO 4 , filter, and evaporate in vacuo to give the title compound. 1 H NMR (CDCl 3 , 300 MHz) δ2.52 (m, 2H), 2.75 (m, 2H), 3.91 (d, J=6 Hz, 2H), 6.65 (d, J=82.5 Hz, 1H), 6.95 (m, 2H), 7.15 (m, 2H).
7.2.2 Synthesis of (E)-1-chloro-2-(fluoromethylene)-4-(p-fluorophenyl)butane
Scheme A, step 7:
Combine oxalyl chloride (25.2 g, 0.198 mol) and toluene (200 mL). Cool to -5° C. Add N,N-dimethylformamide (15.0 g, 0.21 mol) as a solution in toluene (20 mL). Warm to 25° C. After 30 minutes, add a solution of (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butan-1-ol (24.7 g, 30% by weight in toluene, 0.124 mol). After 18 hours, add water (500 mL) and stir for 30 minutes. Separate the organic layer, dry over Na 2 SO 4 , filter, and evaporate in vacuo to give the title compound.
8.1.1 Synthesis of (E)-N-(2-(fluoromethylene)-4-(p-fluorophenyl)butyl)-N-formyl formamide
Scheme A, step 8: ##STR12##
Combine sodium diformylamide (28.8 g, 0.31 mol), acetonitrile (360 g), and N,N-dimethylformamide (48 g). Add (E)-1-chloro-2-(fluoromethylene)-4-(p-fluorophenyl)butane (50.6 g, 0.23 mol). Heat to reflux. After 5 hours, cool to ambient temperature. Add water (466 g) and stir for 15 minutes. After 30 minutes, the aqueous layer is removed. Evaporate the organic layer in vacuo to give the title compound. 1 H NMR (CDCl 3 , 300 MHz) δ2.28 (m, 2H), 2.72 (m, 2H), 4.07 (d , J=3Hz, 2H), 6.74 (d, J=81Hz, 1H), 6.94 (m, 2H), 7.13 (m, 2H), 8.73 (s, 2H).
8.1.2 Synthesis of (E)-N-(2-(fluoromethylene)-4-(p-fluorophenyl)butyl)-N-formyl formamide
Scheme A, step 8:
Combine sodium diformylamide (70 lb) and acetonitrile (903 lb). With agitation, add N,N-dimethylformamide (119 lb). Add a solution of (E)-1-chloro-2-(fluoromethylene)-4-(p-fluorophenyl)butane (126 lb) in toluene. Warm to 80° C. After 6 hours, add a 10% by weight solution of sodium chloride in water (1168 lb). Agitate for 15 minutes, separate the layers. Remove the organic layer to give the title compound as a solution in acetonitrile/N,N-dimethylformamide.
9.1.1 Synthesis of (E)-1-amino-2-(fluoromethylene)-4-(p-fluorophenyl)butane hydrochloride salt
Scheme A, step 9 and Scheme A, optional step 10: ##STR13##
Combine (E)-N-(2-(fluoromethylene)-4-(p-fluorophenyl)butyl)-N-formyl formamide (8.0 g, 32.7 mmol), ethanol (19.9 g), water (29.8 g), and aqueous 12M hydrochloric acid solution (13.1 g). Heat to reflux. After 1 hour, add toluene (29.8 g). Cool to 25° C. Separate the layers. Distill the aqueous layer until the volume is reduced by about two thirds. Cool to 50° C. Add concentrated aqueous hydrochloric acid solution (50 g). Cool to -5° C., filter , rinse with toluene, and dry in vacuo at 60° C. to give a solid. Recrystallize the solid from isopropyl acetate, filter, and dry in vacuo at 43° C. to give the title compound: mp 130°-131.5° C. 1H NMR (D20, 300 MHz) 8 2.50 (m, 2H), 2.79 (m, 2H), 3.47 (d, J=3.0 Hz, 2H), 6.80 (d, J=81.9 Hz, 1H), 7.09 (m, 2H), 7.28 (m, 2H).
9.1.2 Synthesis of (E)-1-amino-2-(fluoromethylene)-4-(p-fluorophenyl)butane hydrochloride salt
Scheme A, step 9 and Scheme A, optional step 10:
Evaporate a acetonitrile/N,N-dimethylformamide solution of crude (E) -N-(2-(fluoromethylene)-4-(p-fluorophenyl)butyl) -N-formyl formamide as prepared in Example 8.1. 2 (1951.5 lb, 12.9% by weight of (E)-N-(2(fluoromethylene)-4-(p-fluorophenyl)butyl)-N-formyl formamide) Combine (E)-N-(2-(fluoromethylene)-4-(p-fluorophenyl) butyl)-N-formyl formamide (252 lb) obtained by evaporation above, ethanol (504 lb), water (760), and aqueous 12M hydrochloric acid solution (328 lb). Heat to 81° C.-89° C. After 2.5 hour, add toluene (784 lb) stir and separate the layers. Evaporate the aqueous layer in vacuo until about 80-110 gallons of liquid remain. Add concentrated aqueous hydrochloric acid solution (1678 lb). Cool to 0° C. over 6 hours, to give a solid. Collect the solid by filtration, rinse with toluene, and dry in vacuo at 60° C. to give the title compound.
Process for crystallizing alkali metal salts of diformylamide
10.1 Synthesis and Crystallization of sodium diformylamide
Combine a solution of sodium methoxide (801.6 g, 25% by weight in methanol, 3.71 mol) and formamide (334 g, 7.42 mol). After 1 hour, heat to reflux. Remove methanolic ammonia by distillation. Continue the distillation, add toluene (800 g) dropwise at a rate approximately equal to the rate of solvent loss. Distill until the temperature of the still head reaches 110° C. Cool to ambient temperature, filter and dry to give sodium diformylamide as a granular solid: mp 185-190 (dec).
10.2 Crystallization of sodium diformylamide
Combine sodium diformylamide (352.5 g, 3.71 mol) and methanol (290 g) in a suitable distillation apparatus. Heat until methanol begins to distill. As the distillation proceeds, add toluene (800 g) dropwise at a rate approximately equal to the rate of solvent loss. Distill until the temperature of the still head reaches 110° C. Cool to ambient temperature, filter and dry to give sodium diformylamide.
10.3 Crystallization of potassium diformylamide
Combine potassium diformylamide (392 g, 3.5 mol) and ethanol (400 g) in a suitable distillation apparatus. Heat until ethanol begins to distill. As the distillation proceeds, add toluene (1000 g) dropwise at a rate approximately equal to the rate of solvent loss. Distill until the temperature of the still head reaches 110° C. Cool to ambient temperature, filter and dry to give potassium diformylamide. | The present invention relates to a novel process for preparing (E)-1-amino-2-(fluoromethylene)-4-(p-fluorophenyl)butane, also known in the art as (E)-(p-fluorophenethyl)-3-fluoroallylamine, novel intermediates thereof, a novel process for the preparing (E)-2-(fluoromethylene)-4-(p-fluorophenyl)butan-1-ol, and a novel process for preparing alkali metal salts of diformylamide. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of and claims priority to U.S. patent application Ser. No. 14/537,155, filed Nov. 10, 2014, the entire disclosure of which is incorporated herein by reference, which claims priority to Japanese Patent Application No. 2013-232688, filed Nov. 11, 2013, the priority of which is also claimed here.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to advanced humid air gas turbine systems. Specifically, the invention relates to an advanced humid air gas turbine system that recovers moisture from exhaust gas after combustion and recycles it as humid air.
[0004] 2. Description of the Related Art
[0005] In the operation of a gas turbine system, it is widely known in the art that steam is introduced into compressed air for combustion in order to improve power generation efficiency. This is because the introduction of steam increases the amount of working fluid, i.e., the compressed air for combustion to reduce the power necessary for a compressor to work.
[0006] The advanced humid air gas turbine system (hereinafter, referred to as AHAT) exemplified in JP-2010-255456-A is configured as follows. Steam introduced into a gas turbine from exhaust gas after combustion is condensed and recovered as recovered water. Impurities are removed from the recovered water with the use of an impurity removing device. Such recovered water is used to humidify the compressed air for combustion to be turned into humid compressed air for combustion. This system allows the heat present in the exhaust gas after combustion to be recovered to the inlet side of the combustor, which in turn raises the temperature of the compressed air for combustion. The system further improves the power generation efficiency as a result of the reduction in the fuel consumption.
SUMMARY OF THE INVENTION
[0007] The AHAT includes a water recovery system for recovering moisture from the exhaust gas of the gas turbine and a superheated steam generation system for generating superheated steam in the heat recovery steam generator that uses the exhaust gas of the gas turbine as a heat source. The superheated steam generated in the superheated steam generation system is introduced into the compressed air for combustion in the gas turbine.
[0008] Incidentally, in the operation of the gas turbine, superheated steam is not introduced into compressed air for combustion in order to prevent moisture from being condensed in the gas turbine at the time of start-up and shut-down. Also in the case of operation after load rejection has been carried out due to a system failure or the like during the operation of the gas turbine system, superheated steam is not introduced into compressed air for combustion.
[0009] If such a gas turbine cannot introduce superheated steam, the conventional AHAT is operated such that the superheated steam generated at a relief valve installed at the outlet of the hear recovery steam generator is discharged to the outside of the system.
[0010] When the AHAT is operated with DSS (Daily Start and Stop) cycles or it takes a long period of time until resynchronization after the load rejection, the amount of consumed water will increase. The increased amount of makeup water results in a rising running cost.
[0011] The present invention has been made in view of above-mentioned situations and aims to provide a water-saving type advanced humid air gas turbine system that can reduce the amount of makeup water to be supplied from the outside by reducing the amount of consumed water when the gas turbine system is starting up, shut down or subjected to load rejection.
[0012] To solve the foregoing problems, an aspect of the present invention incorporates, for example, the arrangements of the appended claims. This application includes a plurality of means for solving the problems. An exemplary aspect of the present invention provides an advanced humid air gas turbine system (AHAT) including: a gas turbine system; a heat recovery steam generator for generating steam by use of exhaust gas from a turbine; a water recovery system disposed on the downstream side of the heat recovery steam generator, the water recovery system recovering moisture contained in the exhaust gas; a first steam system for supplying steam, coming from the heat recovery steam generator, to a compressed air header; and a second steam system for supplying steam, coming from the heat recovery steam generator, to the heat recovery steam generator or the water recovery system. The gas turbine system includes a compressor for compressing air, the compressed air header for mixing high-pressure air introduced from the compressor with steam so as to generate humidified combustion air, a combustor for mixing the combustion air from the compressed air header with fuel for sake of combustion so as to generate combustion gas, and the turbine driven by the combustion gas that is generated by the combustor. When the gas turbine system is starting up, shut down or subjected to load rejection, steam coming from the heat recovery steam generator is recovered by blocking the first steam system and making the second steam system communicate with the heat recovery steam generator.
[0013] According to the present invention, the bypass system which bypasses the gas turbine and leads the generated steam into the system of the advanced humid air gas turbine system is installed at the steam outlet of the heat recovery steam generator. The amount of water consumed when the gas turbine is starting up, shut down, or subjected to load rejection can be reduced. The amount of makeup water to be supplied from the outside when the gas turbine is starting up, shut down, or subjected to load rejection can be reduced. Thus, a reduction in starting up cost can be achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic configuration diagram illustrating a first embodiment of an AHAT of the present invention;
[0015] FIG. 2 is a schematic configuration diagram illustrating a second embodiment of an AHAT of the present invention; and
[0016] FIG. 3 is a schematic configuration diagram illustrating a third embodiment of an AHAT of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Preferred embodiments of an AHAT of the present invention will hereinafter be described with reference to the drawings.
First Embodiment
[0018] FIG. 1 is a schematic configuration diagram illustrating a first embodiment of the AHAT of the present invention.
[0019] The AHAT includes a gas turbine system, a heat recovery steam generator 10 and a water recovery system 6 as a basic configuration. The gas turbine system includes a compressor 1 , a compressed air header 2 , a combustor 3 , a turbine 4 , a drive shaft 1 A, and a generator 5 . The compressor 1 , the turbine 4 , and the generator 5 are mechanically connected to one another by means of the drive shaft 1 A.
[0020] The compressor 1 sucks and compresses outside air and supplies the compressed air as combustion air to the compressed air header 2 via a flow passage 51 . The compressed air header 2 mixes superheated steam with the combustion air to generate humidified combustion air. The superheated steam is supplied from a superheater 14 of the heat recovery steam generator 10 via a pipe 52 and a pipe 55 to the compressed air header 2 . The combustor 3 mixes the humidified combustion air supplied thereto via a flow passage 53 with fuel F supplied thereto via a pipe 50 for combustion to generate high-temperature and high-pressure combustion gas. This combustion gas is introduced via a flow passage 54 to the turbine 4 to drive the turbine 4 , thereby driving the compressor 1 and the generator 5 via the drive shaft 1 A. The rotary power of the turbine 4 is converted into electricity by the generator 5 .
[0021] The heat recovery steam generator 10 is equipment that uses, as a heat source, exhaust gas that has driven the turbine 4 in the gas turbine system to generate steam. The heat recovery steam generator 10 includes a box-shaped casing 10 a which covers its outer circumferential portion with a lagging material; an upstream opening portion provided on the upstream side of the casing 10 a and connected to a duct 60 adapted to introduce exhaust gas that has driven the turbine 4 ; an exhaust gas passage through which the exhaust gas introduced from the upstream opening portion flows; a heat exchanger group; and a downstream opening portion provided on the downstream side of the casing 10 a and adapted to supply the exhaust gas having passed through the heat exchanger group to a water recover system 6 . The heat exchanger group is composed of the superheater 14 , an evaporator 13 equipped with a steam drum 31 , a high-temperature economizer 12 and a low-temperature economizer 11 , which are arranged in this order from the upstream in the exhaust gas passage.
[0022] In the present embodiment, a steam nozzle 15 for jetting superheated steam in the direction of the exhaust gas passage is provided on the upstream side of the superheater 14 in the exhaust gas passage of the heat recovery steam generator 10 . A pipe 58 is connected at one end thereof to the header of the steam nozzle 15 . The pipe 58 has the other end coupled to a branch portion 56 provided on the pipe 55 connecting the heater 14 of the heat recovery steam generator 10 to the compressed air header 2 . A steam nozzle adjusting valve 91 and an orifice 100 are provided on the pipe 58 , the steam nozzle adjusting valve 91 being adapted to adjust the flow rate of superheated steam supplied to the steam nozzle 15 . The steam nozzle adjusting valve 91 is closed during normal operation.
[0023] In the present embodiment, the lower structure of the casing 10 a corresponding to the bottom of the heat recovery steam generator 10 is designed as an inclined structure 16 where the inclination descends from the upstream side toward the downstream side. A pipe 82 is provided at a minimum height portion on the most-downstream side of the inclined structure 16 . This pipe 82 is made to communicate with a drain tank 32 for storing drain. The drain stored in the drain tank 32 is discharged to the outside of the AHAT by means of a pipe 83 arranged to extend toward the outside thereof, and a drain pump 41 installed on the pipe 83 .
[0024] The water recovery system 6 sprays cooling water from a spray nozzle 120 to the exhaust gas from the heat recovery steam generator 10 to condense the moisture in the exhaust gas into water. The water recovery system 6 mixes such water with cooling water and recovers the mixture as recovery water 20 . The remaining gas component resulting from removing the moisture from the exhaust gas is discharged to the atmosphere from a funnel 110 provided on the upper portion of the water recovery system 6 . As the cooling water to be sprayed from the spray nozzle 120 , the recovery water 20 is used that is supplied from the lower portion of the water recovery system 6 via a pipe 81 to an outside cooler (not shown) in which the water is cooled. The recovery water 20 supplied to the outside cooler for cooling may be purified with a water processing device (not shown) and the purified water may be reused as the feed water of the exhaust recovery boiler 10 .
[0025] During the normal operation of the gas turbine system, the exhaust gas having driven the turbine 4 is supplied via the duct 60 to the heat recovery steam generator 10 before being subjected to heat exchange with the feed water or steam flowing inside the above-mentioned heat exchanger group. The superheated steam, generated from the superheater 14 due to such heat exchange, after passing through the pipe 55 connecting the superheater 14 to a superheated steam adjusting valve 90 , is supplied to the compressed air header 2 via the superheated steam adjusting valve 90 and the pipe 52 . The superheated steam adjusting valve 90 reduces the pressure inside the superheated steam to a pressure necessary for the gas turbine system to work. As a result, humidified air to be supplied to the combustor 3 is generated.
[0026] Moreover, during the normal operation of the gas turbine system, water is supplied from the outside via a pipe 70 to the low-temperature economizer 11 . This water is subjected to heat exchange in the low-temperature economizer 11 and is then supplied via a pipe 74 to a deaerator 30 for deaeration of the water. Thereafter, such water passes through a pipe 73 and is increased in pressure at a feed-water pump 40 . Then, the water is supplied via a pipe 72 to the high-temperature economizer 12 , in which the water is subjected to heat exchange. The water leaving the high-temperature economizer 12 is supplied to the steam drum 31 via a pipe 78 and a pipe 76 .
[0027] The water supplied to the steam drum 31 is circulated and heated through the evaporator 13 , a pipe 79 , and a pipe 80 . Water and steam are separated from each other in the steam drum 31 . The steam is supplied via a pipe 57 to the superheater 14 . The steam supplied to the superheater 14 is further heated to be turned into superheated steam, which is supplied to the pipe 55 .
[0028] A description will now be given of how the gas turbine system in the present embodiment is operated at the time of starting up and shut-down.
[0029] When moisture is prevented from being condensed in the gas turbine, such as when the gas turbine system is starting up or shut down, and when steam is not needed as after load rejection, a steam nozzle adjusting valve 91 is operatively opened and, at the same time, a superheated steam adjusting valve 90 is operatively closed first. In this way, superheated steam, led to the pipe 58 , is jetted from the steam nozzle 15 toward the direction of the exhaust gas passage of the heat recovery steam generator 10 . In addition, the inflow of the superheated steam toward the gas turbine is blocked.
[0030] The superheated steam jetted from the steam nozzle 15 toward the direction of the exhaust gas passage of the heat recovery steam generator 10 could be drained after being condensed with the high-temperature economizer 12 or the low-temperature economizer 13 in the heat recovery steam generator 10 in some cases. Such drain passes through the inclined structure 16 of the lower portion of the casing 10 a of the heat recovery steam generator 10 , goes through the minimum height portion on the most-downstream side and is stored in the drain tank 32 . Then, the drain is discharged by the drain pump 41 to the outside of the system of the AHAT.
[0031] According to the first embodiment of the AHAT of the present invention described above, the bypass system is installed at the steam outlet of the heat recovery steam generator 10 . The bypass system bypasses the gas turbine and leads the generated steam into the inside of the system of the AHAT. Therefore, the amount of water consumed when the gas turbine is starting up, shut down, or subjected to load rejection can be reduced. As a result, the amount of makeup water to be supplied from the outside when the gas turbine is starting up, shut down, or subjected to load rejection can be reduced. Therefore, a reduction in starting up cost can be achieved.
[0032] The present embodiment describes as an example the case where the steam nozzle 15 is installed on the most-upstream side of the exhaust gas passage of heat recovery steam generator 10 . However, the present invention is not limited to this. The steam nozzle 15 can also be disposed on areas where the following conditions are met: the exhaust gas temperature in the exhaust gas passage of the heat recovery steam generator 10 is higher than saturated temperature corresponding to the inner pressure of the steam drum 31 ; and water condensation does not occur at the installation portion of the exhaust nozzle 15 . These conditions are in order to avoid the problem such as a thermal shock. For example, a configuration is available in which the steam nozzle 15 is installed between the evaporator 13 and the superheater 14 . Another possible configuration is that in which the evaporator 13 is divided into two evaporators and the steam nozzle 15 is installed between such two evaporators 13 .
[0033] The present embodiment describes as an example the case where the drain discharge system including the drain pipe 82 , the drain tank 32 , and the drain pump 41 is provided to discharge the drain in the heat recovery steam generator 10 . However, the present invention is not limited to this. The present embodiment may be configured such that drain can directly be discharged from the inclined structure 16 to the water recovery system 6 . In this way, the drain discharge system can be omitted.
Second Embodiment
[0034] A second embodiment of an AHAT according to the present invention is hereinafter described with reference to the drawings. FIG. 2 is a schematic configuration diagram illustrating a second embodiment of the AHAT of the present invention. In FIG. 2 , the same reference numerals as those in FIG. 1 denote like portions and their detailed explanations are thus omitted.
[0035] The AHAT according to the second embodiment of the present invention shown in FIG. 2 is composed of almost the same devices as those in the first embodiment but is different from that of the first embodiment in the following configuration. In the present embodiment, the steam nozzle 15 is installed inside the water recovery system 6 . The drain exhaust system including the drain pipe 82 , the drain tank 32 , and the drain pump 41 is omitted. The lower portion of the casing 10 a of the heat recovery steam generator 10 is configured not to have the inclined structure but to have a flat structure.
[0036] In the second embodiment of the AHAT, when moisture is prevented from being condensed in the gas turbine, such as when the gas turbine system is starting up or shut down, and when steam is not needed as after load rejection, a steam nozzle adjusting valve 91 is operatively opened and, at the same time, a superheated steam adjusting valve 90 is operatively closed first. As a result, superheated steam, led to the pipe 58 , is jetted from the steam nozzle 15 toward the inside of the water recovery system 6 . In addition, the inflow of the superheated steam toward the gas turbine is blocked. The superheated steam jetted into the water recovery system 6 is condensed into recovery water 20 by use of the cooling water jetted from a spray nozzle 120 . The recovery water 20 is recovered into the system of the AHAT.
[0037] Incidentally, the superheated steam jetted from the steam nozzle 15 is of a high temperature, which deviates from the temperature conditions inside the water recovery system 6 . However, the steam nozzle 15 is arranged so as not to come into direct contact with members constituting the water recovery system 6 . Thus, the water recovery system 6 can be designed on the basis of normal operational specifications.
[0038] The second embodiment of the AHAT of the present invention described above can produce the same advantages as those of the first embodiment.
[0039] According to the second embodiment of the AHAT of the present invention, drain is unlikely to occur in the heat recovery steam generator 10 . It is not necessary to install the drain discharge system and to configure the lower portion of the casing 10 a of the heat recovery steam generator 10 as the inclined structure. Accordingly, production costs can be reduced.
Third Embodiment
[0040] A third embodiment of an AHAT according to the present invention will hereinafter be described with reference to the drawings. FIG. 3 is a schematic configuration diagram illustrating the third embodiment of the AHAT of the present invention. In FIG. 3 , the same reference numerals as those in FIG. 1 denote like portions and their detailed explanations are thus omitted.
[0041] The AHAT according to the third embodiment of the present invention shown in FIG. 3 is composed of almost the same devices as those in the first embodiment but is different from that of the first embodiment in the following configuration. The pipe 58 is connected at one end thereof to the branch portion 56 of the pipe 55 and at the other end to the cooler of the gas turbine system. The drain exhaust system including the drain pipe 82 , the drain tank 32 , and the drain pump 41 is omitted. The lower portion of the casing 10 a of the heat recovery steam generator 10 is configured so as not to have the inclined structure but to have a flat structure.
[0042] In the third embodiment of the AHAT, when moisture is prevented from being condensed in the gas turbine, such as when the gas turbine system is starting up or shut down, and when steam is not needed as after load rejection, a steam nozzle adjusting valve 91 is operatively opened and, at the same time, a superheated steam adjusting valve 90 is operatively closed first. As a result, superheated steam is led to the pipe 58 and the inflow of the superheated steam toward the gas turbine is blocked. The superheated steam led to the pipe 58 is condensed for reuse by use of the cooler located on the outside of the system of the AHAT.
[0043] The third embodiment of the AHAT of the present invention described above can produce the same advantages as those of the first embodiment. | One of the objects of the invention is to provide a water-saving type advanced humid air gas turbine system (AHAT) that can decrease the amount of makeup water to be supplied from the outside, by reducing the amount of water consumed when the gas turbine system is starting up, shut down, or subjected to load rejection. The gas turbine system includes a compressor, the compressed air header for generating humidified combustion air, a combustor for generating combustion gas, and the turbine. When the gas turbine system is starting up, shut down or subjected to load rejection, steam coming from the heat recovery steam generator is recovered by blocking the first steam system and making the second steam system communicate with the heat recovery steam generator. | 5 |
BACKGROUND OF THE INVENTION
Classical holograms are most commonly created by recording the complex diffraction pattern of laser light reflected from a physical object. These holograms can reconstruct images of sub-micron detail with superb quality. Ever since the early days of holography, there has been considerable interest in forming holograms of computer generated objects by computing and recording their diffraction patterns. These holograms are usually referred to as computer generated holograms, or CGH's. The computational task is a formidable one because of the enormity of the data required for good imagery. For example, a typical 10 centimeter by 10 centimeter hologram can resolve more than 10 14 image points. Furthermore, no portion of the hologram surface pattern can be completely calculated until the diffraction transformation has been carried out on every one of these resolvable points. This necessitates the use of a rather large active memory; 10 10 bytes for our hypothetical 10×10 centimeter hologram.
Even more problematic is the requirement that, for viewing over a reasonable angle, this information must be deposited into the hologram surface at a density of less than 1 pixel per micron and with about 24 bits of intensity per pixel. Many schemes have been developed for recording in a binary fashion, a process which further reduces the required pixel size.
Holograms can be composed from a multiplicity of independent object view, as was discussed in a paper by King, et al, published in Applied Optics in 1970, entitled "A New Approach to Computer-Generated Holograms." These holograms are the type discussed in this disclosure wherein they are referred to as `composite` holograms. A rather elementary but effective technique for creating composite holograms with computer generated images borrows holographic technology which was developed for other media; most notably cinematography film of physical objects. This process is discussed in a patent by K. Haines which issued in July 1982 as U.S. Pat. No. 4,339,168.
In a common embodiment of this method, many conventional views of an object are collected along a simple linear or circular trajectory. Each of these views is then processed in an optical system to build up portions of a first or storage hologram (sometimes referred to as an h1. This storage hologram bears some similarity to the drum multiplex holograms, examples of which contain fully rendered computer images.
The image from this storage hologram, as with all holographic images, is best reconstructed when the hologram is illuminated with a specific light source located at a predetermined position. Otherwise an image degradation results which is a function of the distance between the image points and the hologram surface. In order to make a hologram which is clearly discernable, even under adverse lighting conditions, one should therefore construct an image-plane hologram in which the image straddles the hologram plane.
In order to make an image-plane hologram, the image from the first hologram is used as an object which is recorded in a second hologram, which is frequently referred to as an h2. The laser light rays which constituted the object of the h1, are reconstructed (a rather unique capability of holography) by reversing the direction of the h reference beam. This results in the construction of a 3D image of the original object, albeit a pseudoscopic or inside-out image, in a space which is now accessible for placement of an h2. The h2 is located on a plane within the image volume.
With many image-plane holograms, the viewability is further enhanced under polychromatic (white light) illumination with the elimination of vertical parallax in the image. Vertical parallax is deleted from the h1 (and the h2 which is derived from it) when a variety of vertical views is not collected. Consequently the viewer is prohibited from seeing over or under an image. The three dimensionality is retained only in the horizontal direction. Holograms which lack vertical parallax are commonly called rainbow holograms because the viewer moving his eyes vertically perceives an image which changes colors throughout the spectrum when the hologram is illuminated with a white light source. Although rainbow holograms contain images with incomplete three dimensionality, economy is realized since the requisite computed views need not span a vertical as well as horizontal range.
The making of a hologram by the procedure just described is laborious. It requires the construction of a first hologram, an h1, which is ultimately obsolete. A direct approach was introduced in U.S. Pat. No. 4,778,262 which was granted in October 1988. That technique requires no h1 construction. Each portion of the computed data is used to create a tiny elemental image-plane hologram directly. These elements are placed side by side to form the composite hologram.
This direct method can be very difficult to implement. The common methods of computer image generation must be highly modified. Otherwise their use will yield images which are unacceptably distorted. In a related process in which normal views of an image (i.e. no image-plane views) are collected, and then recomposited to form elemental views, unorthodox processing is required.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide analytical processes for the construction of a hologram from a computer generated object, the image of which is reconstructed close to or straddling the hologram surface, such processes requiring no lens or first hologram to image the object onto the hologram surface.
It is another object of the present invention to provide transformations which will allow conventional computer-generated image data to be converted into a format which is convenient for construction of a hologram whose image straddles the hologram surface without requiring construction of an intermediate hologram.
It is yet another object of the invention to provide an easy method of computing and recording on a bit-by-bit basis, computer-generated hologram elements which form components of a larger composite hologram.
These objectives and others are accomplished by the methods briefly described in the following. A portion of the object data is used to create each individual small image-plane hologram element. Prior to rendering for the view required of each element, the model is divided into two separate volumes. Each volume represents a portion of the object on either side of the hologram, or primary, plane which passes through the model. This division first requires the insertion of two new clipping planes which are placed imperceptibly close to, but on either side of the primary plane. Additionally, points must be included in these clipping planes to preserve the integrity of the model. This procedure guarantees that (a) no singularities will be present in the latter processing due to points on the primary plane, and (b) distortions in the image will not occur that would otherwise arise due to ambiguities of surfaces which pass through the primary plane. Once these procedures are carried out, transformations unique to this image-plane, direct process may be carried out. After these transformation procedures, conventional rendering methods can be employed for each of the two object volumes. A hierarchical process favors the object volume on the observer side of the hologram for the first surface calculations when the volumes are recomposited. This procedure results in images which retain both vertical and horizontal parallax.
It is often desirable to discard vertical parallax in holographic images of computed data. This presents additional problems when attempts are made to use homogeneous coordinate transformations which are common in computer graphics. Here again, unorthodox procedures are required. These involve the use of a non-homogeneous coordinate transformations and the pre-rendering insertion of a sufficiently fine mesh over the object surface.
A computationally indirect method (although still a direct or one-step hologram construction method) is disclosed in this patent. With this method the required elemental views are obtained by re-sorting the pixels contained in a series of conventionally rendered object views. This sorting transformation is described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the geometry used for calculations of the method.
FIG. 2 is a schematic perspective illustration of an example optical setup for constructing a hologram from transparencies made by techniques of FIG. 1.
FIG. 3 illustrates the geometry used for calculations of the method when vertical image parallax is not included.
FIG. 4 is a schematic perceptive illustration of an example optical setup for constructing a hologram from transparencies made by techniques of FIG. 3.
FIG. 5 illustrates the collection of conventional views of a computer generated image which are collected from viewpoints on a spherical surface.
FIG. 6 illustrates the collection of conventional views of a computer generated object which are collected from viewpoints on a planar surface.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The process of making a hologram directly from computer-generated image data is referred to in this disclosure as a one-step procedure. In this process, small hologram elements are constructed and placed more-or-less contiguously to form a larger composite hologram. The computation of each elemental view required for each hologram element, which is the subject of this disclosure, is described with reference to FIG. 1. The x and y axis lie on the hologram surface 10. A typical hologram element 12 is shown which is located at a distance `a` in the x direction and `b` in the y direction from the center of the coordinate system in the hologram plane. The viewplane (window plane) 20, which contains the array of pixels 22, etc. for this element 12, is selected to be parallel to the hologram plane and displaced from it by a distance z p . Pixels, such as 22, are located on this viewplane by coordinate values x p , y p and z p .
For the typical element 12, the generalized object point 32, located at position x, y, z, in object 30, results in the viewplane point 22. The matrix equation 1 describing this relationship is; ##EQU1##
These matrices are, beginning from the right, an object translation matrix, the one-point perspective transformation matrix "M" (projector from viewpoint to origin is perpendicular to the viewplane), and the perspective matrix. The perspective transformation matrix transforms an arbitrary perspective-projection view volume into a parallel-projection view volume. When used in conjunction with a normalizing matrix, which is omitted here, and with proper selection of the constants C and D, a canonical view volume results.
The views which result from this configuration are rather strange in that the inside surfaces of an opaque object are not visible while external surfaces behind the viewpoint are visible. The viewplane pixels for each viewpoint are calculated by incrementally translating (i.e. changing a and b) in the x, y, 0 plane between each view computation.
A system like that shown in FIG. 2 is used to form the contiguous image-plane hologram elements. It is similar to a system disclosed in U.S. Pat. No. 4,778,262. In the figure, the viewplane projection data for each element 12 is recorded as a transparency 40 and illuminated with a laser. Lens 41 projects the image of the transparency into plane 42, shown in FIG. 2 to be coincident with the light-concentrating lens 43. The image presented in 40 for the construction of any element, is the viewplane projection which was computed for that viewpoint. The final result is that the laser light rays passing through every part of the composite hologram 10 simulate the computed rays passing through that same element. This simple equivalence disregards any scale changes which may be required. The reference beam 18 is required for the construction of each of the hologram elements, but uniquely for these hologram elements, the required laser beam coherence length can be very short. It need not exceed the dimension of the element.
The removal of vertical parallax is often a practical necessity for improved image visibility and reduced computation. The technique used to create these elemental rainbow holograms is somewhat of a hybrid, as shown in FIGS. 3 and 4. In the horizontal direction (dealing with vertical lines only) the geometry is like that of FIG. i. The viewpoint is located on element 14 within the object's primary plane. But, in the vertical direction the viewpoint is selected to mimic the position of the completed hologram viewer's eye, shown as 13 in FIG. 3. The combination results in hologram elements 14 which are tall and narrow and which are laid down side by side. FIG. 4 illustrates a method of hologram reconstruction. While the procedure is similar to that shown in FIG. 2, it requires that the hologram be translated in the horizontal direction only during construction.
Note that the spherical lens 43 of FIG. 2 has be replaced by the lens pair 45 and 46. Lens 45 is a spherical lens and lens 46 is a cylindrical lens. For the special case in which the hologram is meant to be viewed from relatively large distances, the spherical lens 45 essentially collimates the light which enters it from lens 41 and the film transparency 40. Thus all of the rays pass through the hologram element 14 in horizontal sheets which are parallel to each other.
In this discussion, scaling, has been disregarded since it is a function of the film size and lens magnification.
Insight into the modeling required for the geometry of FIG. 3, may be gained from the examination of a method which uses standard software routines. A taper routine is first used to compress a rectangular object volume into a wedge whose vertex runs along the x axis. The taper routine leaves object points on the z=z p plane unaltered, but locates those close to the z=0 plane almost on the y=0 plane. In the next operation, the eyepoint is moved close to the origin and the appropriate perspective transformation yields the correct view data for the required elemental hologram strip. The unmodified taper routine may be used for objects confined to the z>0 volume. It cannot be used for objects subtending the z=0 plane.
In order to construct the elemental views required for vertical parallax removal, the x and y coordinates are treated differently. Homogeneous coordinate system matrices, like those of equation (1), can no longer be used. The image point 23 in the viewplane 21 has coordinates x p , y p , z p which are related to the x, y, z coordinates of the object point 33 in the following manner: ##EQU2##
An important and elegant aspect of the homogeneous coordinate system perspective transformation matrix "M", as used in equation (1), is that it preserves relative depth, straight lines and planes. This preservation greatly facilitates the subsequent operations. The scan-line conversion process faithfully fills in all the points interior to bounded planar primitive edges, which were originally omitted in the modeling. That is, no ambiguities in the z value exist for the interior points. Unfortunately, neither straight lines nor planes are preserved by the transformation of equation (2), nor, for that matter are they with the "taper" transformed vectors. Edges my be preserved by adding sufficient edge points prior to transformation. Even with these additions, planes are transformed into distorted surfaces whose edges no longer adequately define the location of interior points.
Unfortunately the scan-line conversion process locates these interior points on lines (usually horizontal) joining edge points. This deficiency manifests itself as incorrect first surface determinations throughout the interior of the primitives.
A corrective procedure places a sufficiently fine mesh into each pre-transformed surface. Of course, as the mesh fineness becomes greater, the process approaches that of scan converting prior to transformation, and the transformation procedure may become compute intensive.
Additional problems arise in dealing with objects which subtend the z=0 axis. These problems cannot be disregarded with image-plane holograms of either the rainbow or full-parallax variety. In general, the procedure is computationally unorthodox because surfaces cannot be excluded even though they are behind the viewpoint. This is a departure from conventional methods because a clipping plane is usually provided which prohibits inclusion of images behind this viewpoint. Moving this clipping plane as required for the present system is not fundamentally difficult, but it is accompanied by other problems. First is the obvious one of singularities for object points in the z=0 plane. This can be handled by moving these points into a new plane which is just slightly removed from z=0. But another subtle problem remains. Polygons whose boundaries are entirely contained in that portion of the view volume beyond the viewpoint i.e. with z>0, are handled in the usual way. Similarly, polygons with all boundaries in the volume z<0 are peculiar only in that their projections are inverted. But, polygons whose edges intersect the z=0 plane, are transformed by equation (1) or (2) into figures with discontinuous edges. These discontinuities are a result of the inversion experienced by the edges in traversing the z=0 plane. Since this transformation is performed prior to scan line conversion and filling, a continuity of edges must be reestablished. A procedure which rectifies this problem requires the insertion of two more clipping planes which are placed close to, and on either side of the z=0 axis. The object is effectively divided into two portions prior to the perspective transformation. One portion is restricted to the volume z>0, and the other is restricted to the volume z<0. An absence of planes which traverse the z=0 axis is thus guaranteed.
There is another way in which the required elemental views may be generated. With this method many fully rendered conventional views of the computer generated object are collected. In FIG. 5, these views are computed for viewpoints, such-as viewpoint 50, which lie on a spherical surface of radius `d` which is centered at the coordinate system origin 15 in the hologram surface 10. These conventional viewplane projections contain enough information to build the required views for the elements in the hologram plane which passes through the object. Optimum utilization of the technique requires that each of the original viewplane projection pixels, whose viewpoint orientation is designated by the angles α and φ in FIG. 5, be reassigned to elements whose location in the hologram plane 10 is given by ##EQU3## where x p ', y p ' is the pixel location in the original viewplane. The prime superscript has been added here to avoid confusion with the coordinates of the new elemental view projection plane. The positions of the pixels within the new elemental projection plane 20 are,
This sorting operation must be carried out for all of the original viewplane projections. This analysis is applicable only to the case for which the original views are calculated from viewpoints spaced across a spherical (or cylindrical if vertical parallax is missing) surface centered on the origin.
In FIG. 6, the original views are collected from viewpoints which lie on a plane located at some distance `e` from the desired hologram plane rather than on a spherical surface located at radius `d` from point 15 within the hologram plane. In figure 6, the viewpoint 51 has been translated in the x and y positions by distances q and r respectively. For this geometry, the original viewplane pixel, with coordinates x p ', y p ', is reassigned to the element 12 whose location in the hologram plane 10 is given by ##EQU4##
The new pixel position 22 at x p , y p in this new elemental projection plane is ##EQU5##
Here again the sorting must be carried out for all of the pixels in each of the original viewplane projections.
When these post-rendering methods which were just described are applied to objects which lack vertical parallax, the procedure is simplified. For example, if the original views are collected from positions on an arc centered on the origin (point 15 in FIG. 5), the original pixels are reassigned to elemental strips, like 14 in FIG. 4. By setting φ=0 in equation (3), the position of this elemental strip in the z=0 plane is determined to be, ##EQU6##
Similarly, by setting φ=0 in equation (4), the x position of the pixels in the elemental viewplane is, ##EQU7##
The y position results from a simple modification of the above equations. It can be shown to be, ##EQU8##
Similarly by eliminating vertical parallax and collecting views along a straight line which is parallel to the hologram plane, the element 14 to which the pixels are reassigned is determined by setting r=0 in equation (5).
a=x.sub.p '+q (10)
Also by setting r=0 in equation (6) ##EQU9##
The y position can be shown to be ##EQU10##
This geometry is unique because it is the only situation for which a pixel reassignment calculation is not required for every one of the original pixels.
This economy in the reassignment computation may be realized because each column of pixels (strip with constant x dimension) may be relocated intact to a pixel column in the new elemental viewplane. That is, pixels at different vertical levels (different values of y) in any column do not end up in different horizontal positions (different values of x) in the new elemental viewplanes. Also the relative y values are retained.
The simple system which maintains pixel column integrity in the reassignment process is similar to a method previously disclosed in a patent titled "System for Synthesizing Strip Multiplexed Holograms", U.S. Pat. No. 4,411,489, which issued in October 1983. That patent describes a method in which entire strips, which are several pixels wide, from conventionally collected views are transferred into a new viewplane for an image-plane hologram. In general the optimum and preferred process requires that each pixel in the original viewplanes be reassigned to a new pixel location, independently of adjacent or nearby pixels. The only situation for which this is not the case is that in which columns of the original views, each a single pixel in width, are reassigned to new column positions when the original views are collected (or computed) along a straight line path which is parallel to the plane of a flat, rainbow, composited hologram. Otherwise the process of transferring columns of original data intact into the new image-plane hologram viewplanes will lead to images having undesirable distortions and aberrations.
Configurations other than those presented in this disclosure may be used. For example, a more generalized analysis can be constructed for a so-called three point perspective projection in which the line-of-sight is not normal to the projection plane and viewplane, as it is in the foregoing. Also it should be noted, that with analytical modification, the methods described may be extended to handle hologram surfaces which are not flat; for example cylindrical holograms suitable for bottle labels.
Using systems like those shown in FIGS. 2 and 4 with the alternative, post-rendering method, should result in images which match the more direct methods previously discussed with reference to FIG. 1. One of the drawbacks of the post-rendering method however is that sufficiently large storage must be provided into which all of the original views are placed prior to initiation of primary-plane element construction.
It should be recognized that with the post-rendering techniques, other types of input data such as that obtained from cinema or video, may substitute for or embellish computer-generated imagery. For example video views of a real object can be digitized and processed in the same way as the viewplane data generated from a computer object.
Certain types of images common to holography, are particularly easy to handle with the procedures described herein. One of these images is the 2-D (two dimensional) image which lies on the hologram plane. Each projection plane 20 in FIG. 1 (or 21 in FIG. 3) is a uniform function containing no variations across the surface. Each pixel is identical to the others in every projection plane. Only the transmissivity of the transparencies 40 in FIG. 2 or FIG. 3, are different from each hologram element.
If the image is a single planar image which does not alter as one views it from different directions, but which is not on the hologram surface, then each projection plane view is a slightly different sample of this planar image. Adjacent views are identical except for a slight translation of area of the projection plane which is sampled. Furthermore, the required resolution at each image plane view is reduced as the distance from the planar image to the hologram declines. Images restricted to several such planes are similarly relatively easily handled.
A rule in optics states that rays which come to focus with resolution δ in some primary plane (In a preferred embodiment of this patent, the primary plane is the hologram plane itself.), must approximately subtend an angle Ω where ##EQU11## λ is the wavelength of light used for the imaging. Furthermore this resolution of δ can be maintained over an image depth, z m , of no more than ##EQU12##
Object points located at greater distances that z m from the primary plane are reconstructed with resolutions of ##EQU13##
Evidently increasing the resolution in the primary image plane results in a reduction in the resolution of other image points. From these observations, a method of determining the image resolution required of the computation may be established as follows. First, select a desired pixel resolution δ. Next, determine from equation (14) if the image depth over which this resolution can be maintained is adequate. If it is not, increase δ to an acceptable limit. Finally, compute new ray directions through the object points at angles separated by Ω determined from equation (13). Smaller increments are redundant and do not serve to increase the holographic image resolution.
For this analysis, the size of the element δ is a single resolvable pixel in width. In this case, and using the method of resolution determination described here, the resulting projection plane data comprise the Fourier Transform of the pattern within this pixel. This means that a computer-generated hologram (bit-by-bit computation of the hologram element itself) for each element may be easily computed from this projection plane data. An entire composite hologram may be built up in this manner, and does not require the large storage needed for a true CGH as described previously.
Equations (13) and (14) can be recognized as the resolution and depth of focus equations for a conventional camera lens system, where Ω is the F number (lens aperture over the focal length, or image plane distance). Images from composite holograms like those described in this disclosure are like those in photographs obtained with relatively small aperture lenses, except for the one important difference. The image has very good parallax and this is what gives it three dimensionality. This parallax permits an axial or z direction resolution, σ, given by ##EQU14## where β is the range of viewing angles. Composite holograms can match true classical holograms in their parallax capabilities. But classical holograms retain all the z dimensional information and this allows them to have infinite depth of focus since all image points are focused simultaneously. With a classical hologram, adjacent portions of the hologram and different views are not independent of each other. They are related by complex phase relationships as required from diffraction theory.
By incorporating phase relationships between pixels in adjacent projection planes in the composite process described in this disclosure, image resolution is improved, particularly for the image points most distant from the hologram plane. In the limit, as more phase information is recorded, the resulting hologram approaches that of a full computer generated hologram and contains image detail like a classical hologram.
The above description of methods and the construction used are merely illustrative thereof and various changes of the details and the method and construction may be made within the scope of the appended claims. | Computer-processed or computer-generated objects can be used to build holograms whose images are close to or straddle the hologram surface. No preliminary or first hologram is required. The hologram is built up from a number of contiguous, small, elemental pieces. Unorthodox views from inside the object are required for the creation of these elements. One method of generating the views employs unique object manipulations. The computational transformations ensure that no singularities arise and that more-or-less conventional modeling and rendering routines can be used. With a second method, a multiplicity of conventional object views are collected. Then, all pixels in these conventional viewplanes are reassigned to new and different locations in the new viewplanes for the elemental views. These methods may be used to build rainbow holograms or full parallax holograms. When properly executed they are visually indistinguishable from other types. | 6 |
BACKGROUND OF THE INVENTION
An improved process is provided to fade denim fabric employing chemical treatment providing a decreased chemical oxygen demand.
Denim garments such as slacks, jackets and skirts are considered by many to be more fashionable once they have attained a faded, worn appearance. Accordingly, denim fabrics and garments are frequently subjected to a bleaching procedure during their manufacture to give them a bleached, superbleached, rifled or whitewashed appearance. While such prebleached goods are a very marketable product, the bleaching procedures conventionally employed are relatively labor intensive, which adds significantly to the cost of the bleaching process. U.S. Pat. No. 4,218,220 discloses that it is sometimes desirable to prepare prefaded denim garments uniformly faded, that is prefaded blue jeans free of unwanted streaks. Satisfactory, unstreaked, suitably faded blue jeans were hitherto obtained only by repeated washings. The patent teaches subjecting the denim fabric to a washing cycle comprising an initial wash with detergent and emulsifier, a suitable intermediate rinsing operation, a bleaching operation in which the garments are subjected to the simultaneous action of bleach and a fabric softener of the quaternary ammonium type, alone or with the addition of a suitable amount of detergent, a further rinsing operation, and an optional final treatment with fabric softener and laundry sour. The patent teaches the use of a chlorine bleach, such as, sodium hypochlorite or trichloroisocyanuric acid or the like as a bleach. U.S. Pat. No. 4,852,990 teaches a modification wherein denim garments first are desized, then contacted with an aqueous polyacrylic acid solution. A chlorine-type bleaching agent is subsequently added to provide a uniform bleached appearance.
Subsequently, the trend has been toward a look featuring random faded effects.
One such manifestation of this trend is the practice of stone-washing - that is, immersing cloth in water containing no other substance than pumice stones. The effect it is sought to produce on denim treated by this method is one of natural fading, a "used" look characterized by the contrast between light and dark areas; in made-up garments however, the effect tends to appear on and around the seams only, whereas the color of the remaining fabric remains substantially uniform.
U.S. Pat. No. 4,740,213 discloses a process in which granules of a coarse, permeable material, such as pumice, are impregnated with a chlorine bleaching agent tumbled in a drum with denim fabric in a dry state. Subsequent traces of the chlorine bleaching agent are removed, optionally by an antichlor such as acidic hydrogen peroxide.
However, chlorine bleaching agents are known to be very destructive to cotton, consequently alternative bleaching agents have been employed to produce the faded look. Potassium permanganate is very desirable for such an oxidative treatment. When applied in a solution an even fading is obtained, and when impregnated into an inert porous material it provides a desired random uneven oxidation of colorbodies when tumbled with fabric ("rocking"). Unfortunately, dark colored, insoluble manganese dioxide is deposited on the denim resulting in a dirty, stained appearance. The manganese dioxide can be removed by a process called "neutralizing", that is, reducing the manganese dioxide to soluble manganous salts, usually by sulfites, thiosulfate, hydroxylamine and the like. These reducing agents must be used in a large excess and at a pH of 2.5 to 3.0 causing damage to the cotton fibers. The excess reducing agent from the neutralizing step is very undesirable to dispose of because of its very high toxicity and high chemical oxygen demand.
After neutralizing the denim is frequently "brightened" or bleached to enhance the contrast between the dyed and the decolorized areas. Currently a hypochlorite bleach or a sodium perborate bleach bath is employed for brightening.
BRIEF SUMMARY OF THE INVENTION
The present invention is a process for wet processing denim fabric containing dyestuff colorbodies by desizing the denim fabric, washing the desized fabric, contacting the washed fabric with potassium permanganate to oxidize part of the colorbodies in the denim fabric to a form which is easily removed from the fabric surface, thereby decolorizing the denim fabric, and neutralizing the decolorized denim fabric by removing residues of the potassium permanganate and of the oxidized colorbodies, the improvement comprising the steps of (a) neutralizing the oxidized denim fabric by (i) immersing the denim fabric in about 5 to 20 parts by weight of a first aqueous solution per part by weight denim fabric, (ii) maintaining said first aqueous solution between pH 3.0 and 6.0, (iii) subsequently incorporating about 2 parts by weight of either a monodentate or multidentate carboxylic acid chelating agent or salt or combination thereof, and 1 part by weight hydrogen peroxide, and (iv) maintaining said first aqueous solution at about 65° C. to 90° C. for 5 to 15 minutes, and (b) bleaching the decolorized denim fabric by contacting said denim fabric for 4 to 8 minutes at 65° C. to 90° C. with 5 to 20 parts by weight of an alkaline bleaching solution comprising from about 0.6 to about 4 parts by weight hydrogen peroxide and sufficient alkali to provide a pH of about 8 to 9.
DETAILED DESCRIPTION OF THE INVENTION
Unless otherwise specified percent or parts by weight is on the basis of 100% of undiluted compound by weight. For example, 1 part by weight hydrogen peroxide requires 2 parts by weight of an aqueous solution of 50% H 2 O 2 . However, 3 parts by weight 35% H 2 O 2 is equivalent to about 1 part by weight hydrogen peroxide on a 100% basis.
The denim fabric may be treated in any convenient form such as uncut piece goods, as partially fabricated garments or as finished garments. Denim is conventionally woven with colored warp and white filling threads but would include striped denim fabrics or denim fabrics woven with both warp and filling threads colored. Usually the denims are dyed with vat dyes such as indigo or sulfur dies or the like. Denim fabrics may also be woven with mixtures of cotton and synthetic fibers.
The process is particularly useful for producing a denim with a random faded pattern by the process of desizing the denim fabric, washing the desized fabric, contacting the washed fabric with potassium permanganate to oxidize part of the colorbodies in the denim fabric to a form which is easily removed from the fabric surface, thereby decolorizing the denim fabric, and neutralizing the decolorized denim fabric by removing residues of the potassium permanganate and of the oxidized colorbodies, the improvement comprising the steps of (a) neutralizing the oxidized denim fabric by (i) immersing the denim fabric in about 5 to 20 parts by weight of a first aqueous solution per part by weight denim fabric, (ii) maintaining said first aqueous solution between pH 3.0 and 6.0, (iii) subsequently incorporating about 2 parts by weight of either a monodentate or multidentate carboxylic acid chelating agent or salt or combination thereof, and 1 part by weight hydrogen peroxide, and (iv) maintaining said first aqueous solution at about 652° C. to 90° C. for 5 to 15 minutes, and (b) bleaching the decolorized denim fabric by contacting said denim fabric for 4 to 8 minutes at 65° C. to 90° C. with 5 to 20 parts by weight of an alkaline bleaching solution comprising from about 0.6 to about 4 parts by weight hydrogen peroxide and sufficient alkali to provide a pH of about 8 to 9.
Optionally, the denim fabric may be desized by contacting the denim fabric with an effective amount of a peroxygen compound and 0.2% to 3% surfactant (preferably 1% to 2%) at pH 7-12 (preferably 9-10) for a sufficient time (5-15 minutes, preferably 10-12 minutes), thereby substantially removing sizing therefrom. An effective amount of a peroxygen compound for desizing is desirably 0.5% to 3% sodium persulfate or 2% to 6% hydrogen peroxide (100% basis). This process overcomes the environmentally-undesirable effluents from current desizing processes employing enzymes or sodium perborate.
Either sodium persulfate or hydrogen peroxide are particularly desirable to remove both starch and polyvinyl alcohol, the two types of sizing generally used for weaving denims.
Typical directions for wet finishing denim fabric with a random faded effect are described below for finished garments which have been inverted (turned inside out). As used herein all percentages are by weight; "owg" stands for on weight of goods.
EXAMPLES
Desizing
Add the inverted garments to a large washer. Fill the washer with enough hot water (65°-90° C.; 150°-190° F.) to produce a goods to liquor ratio of 1:20 or less. Add 2%-6% on the weight of the goods (owg) 35% H 2 O 2 (3%-4% owg optimum). Add a wetting agent or surfactant 0.2%-3% owg (1%-2% optimum) and enough alkali to reach a pH of 7-12 (9-10 optimum). React 8-15 minutes (10-12 optimum). Rinse with hot water (65°-90° C.; 150°-190° F.) agitating 4-10 minutes. Repeat rinse as necessary to prevent the redeposition of size.
Sodium persulfate 0.5%-3% owg (1%-2% owg optimum) can be substituted for H 2 O 2 in desizing. Optimum temperature is 80°-85° C. (175°-185° F.).
Neutralizing
After rocking, add the garments to a large washer and fill to the highest level with hot water (65°-90° C.; 150°-190° F.). Add 2%-3% owg neutral detergent. Agitate 4-10 minutes and drain. Begin the neutralization process immediately after the prewash. Fill washer with hot water (65°-90° C.; 150°-190° F.) to a el that yields a goods to liquor ratio of 1:20 or less. Add in the following order: 2 parts glacial acetic acid, 2 parts chelating agent, 3 parts 35% H 2 O 2 . H 2 O 2 35% should be in the range of 2%-5% owg (3%-4% optimum). (The pH of this system is approximately 4, considerably higher than the pH of 2.5-3 obtained when using sulfite or hydroxylamine systems.) At this pH, there is no additional damage to the garment. Agitate 5-15 minutes (10-12 minutes optimum) and drain. Fill washer to the highest level with hot water (65°-90° C.; 150°-190° F.). Agitate 2-6 minutes to rinse and drain. Repeat neutralization step above, but add 1%-4% owg (2%-3% owg optimum) neutral detergent. Following the second neutralization step, fill the washer to the highest level with hot water (65°-90° C.; 150°-190° F.). Agitate 2-6 minutes and drain. Repeat as necessary to remove detergent and establish a neutral rinse pH.
The chelating agents may be any multidentate carboxylic acid based agent, particularly those showing affinity for manganese or promoting the reduction of manganese (VII, V or IV) to manganese II, for example, EDTA (ethylenediamine tetraacetic acid), DTPA (diethylenetriamine pentaacetic acid). A commercial product such as Dow Chemical Corporation's Versenex 80™ which contains >38% pentasodium DTPA and other noninert compounds is particularly convenient.
After removal of insoluble MnO 2 and rock powder, the garments are treated with an alkaline formulation of H 2 O 2 as a replacement for hypochlorite or perborate. This step bleaches the decolorized portions of the garment enhancing the contrast between dyed and decolorized areas.
Bleaching
Immediately following the final rinses of neutralization, fill washer with hot water (65°-90° C.; 150°-190° F.) to a level that produces a goods to liquor ratio of 1:20 or less. Add 2%-5% owg 35% H 2 O 2 (3%-4% owg optimum), optical brightener and enough alkali to yield a pH of 8-9. The pH should not exceed 9.5. Agitate 4-8 minutes and drain. Fill washer to highest level with warm water (35°-50° C.; 90°-120° F.). Agitate 2-4 minutes and drain. Repeat as necessary to yield a rinse pH near neutral. Fill washer with warm water (35°-50° C.; 90°-120° F.) to a level that produces a goods to liquor ratio of 1:20 or less. Add softener and ozone inhibitors. Agitate 4-8 minutes, drain and extract.
EXAMPLE 1
Desizing of Garments-Production Facility
One hundred twenty pair (about 100 kg) of blue denim jeans were inverted and added to a 200 kg capacity washer. The washer was filled to high level with hot water (75° C.) to maintain a goods to liquor weight ratio of 1:20 or less. About 1.8 kg, 35% H 2 O 2 , 85 g nonionic liquid detergent and enough caustic or soda ash to reach a pH of 9 were added; the garments were agitated 7 minutes and drained. The washer was then filled to high level with hot water (75° C.); agitated 4 minutes and drained. Washer was filled again to high level with warm water (45° C.); agitated 4 minutes, drained and extracted.
EXAMPLE 2
Decolorization of Garments-Production Facility
Desized garments were righted and 60 garments (about 50 kg) were added to a tumbler containing 100-150 kg KMnO 4 soaked pumice stones. Stones and garments were tumbled (rocked) together for 20 minutes.
EXAMPLE 3
Clean-up of Decolorized Garments-Production Facility
Garments decolorized in Example 2 appeared brown and gritty. Removal of the brown stain was necessary to obtain the desired appearance. One hundred twenty (about 100 kg) "rocked" jeans were added to a 200 kg capacity washer. Washer was filled to high level with hot water 175° C.; 110 g neutral liquid detergent was added, the garments were agitated 4 minutes and drained. The washer was filled to low level with hot water (75° C.) to maintain a goods to liquor ratio of 1:20 or less. Added in this order were 1.6 kg glacial acetic acid and 1.6 kg of Versenex 80™ chelating agent (Dow Chemical). Then 2.45 kg of 35% H 2 O 2 was added. The garments were agitated 7 minutes and drained. The washer was filled again to high level with hot water (75° C.); 110 g neutral liquid detergent was added; the garments were agitated 2 minutes and drained. Then the washer was filled to low level with hot water; 1.6 kg glacial acetic acid, 1.6 kg chelating agent and 2.45 kg 35% H 2 O 2 were added. The garments were agitated 7 minutes, drained and extracted. The washer was filled to high level with hot water (75° C.), agitated 2 minutes and drained. The rinse was repeated. The washer was then filled to high level with hot water (75° C.); 3.6 kg 35% H 2 O 2 and enough alkali to reach a pH of 9 were added. Garments were agitated 4 minutes and drained. Washer was filled to high level with warm water (45° C.), agitated 2 minutes and drained. The rinse was repeated and garments were extracted.
Garments produced were free of brown discoloration and showed good contrast between dyed (blue) and decolorized (white) areas.
EXAMPLE 4
Desizing-Laboratory
Denim fabric used was supplied by Cone Mills. Fabric was cut into 4"×4" swatches. Desizing was performed on a TERGOTOMETER, United States Testing Co. Swatches were weighed to determine average sample weight. This weight was used in all calculations. Goods to liquor ratio was maintained at 1:20. Eight swatches were added to each station of the TERGOTOMETER and 2% owg of 35% H 2 O 2 and 1.0% owg Rapid Scour (Gist Brocades USA Inc., Charlotte, N.C.) were added. The pH was adjusted to 9 with 1N NaOH and the samples were agitated 12 minutes at 65° C. The desizing liquor was dropped and the samples rinsed with water for 4 minutes at 65° C. The rinse was repeated and the samples air dried.
EXAMPLE 5
Decolorization-Laboratory
Desized samples were added to a 500 mL Erlenmeyer flask (placed flat, face-up). A 2% KMnO 4 solution (50 mL) was added to the flask and reacted 15 minutes at room temperature. The spent solution was dropped and the sample rinsed twice with 100 mL portions of deionized water.
EXAMPLE 6
Clean-up of Decolorized Garments-Laboratory
Immediately following decolorization, samples were reacted with 100 mL neutralization liquor to maintain a goods to liquor ratio of 1:20. Neutralization liquor was prepared by adding 3% owg 35% H 2 O 2 , 2% owg acetic acid and 2% owg chelating agent to deionized water and bringing the volume to 100 mL. Chelating agent used was Versenex 80™ Other polydentate chelating agents may be used and mention of this product is not to limit the scope of this invention. Sample and the liquor were agitated for 10 minutes at 65° C. in an oscillating bath. The liquor was dropped and the neutralization step repeated. After the second neutralization, the liquor was dropped and the sample was brightened by adding 100 mL of a 2% owg H 2 O 2 solution adjusted to pH 9 with NaOH. Sample and liquor were agitated for 10 minutes at 65° C. in an oscillating bath. Following brightening, the sample was rinsed twice with 100 mL portions of deionized water for 2 minutes in the oscillating bath at 65° C. Samples were air dried. | An environmentally improved process is provided to fade denim fabric either as the woven fabric or after being made up into garments. The denim fabric may optionally be uniformly faded, or faded in a random pattern and stone washed. The effluent from the process does not have the disadvantage of the high COD of conventional processes. | 3 |
CROSS-REFERENCE TO RELATED U.S. APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
REFERENCE TO AN APPENDIX SUBMITTED ON COMPACT DISC
[0004] Not applicable.
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The present invention relates to socks with non-slip soles.
[0007] The invention particularly relates to socks with non-slip soles formed by positioning soft plastic material, fabric material, ethyl vinyl acetate (EVA) and preferably leather material onto each other respectively.
[0008] 2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98.
[0009] One of the unexpected accidents that might happen at home or in another environment indoors is that the socks we use tend to slip on the floor. As a result of such accidents, many wounds and injuries occur. In order to prevent such accidents, socks with non-slip soles are used in our day. However, the state of the art non-slip socks have many disadvantages. These disadvantages are mentioned below.
[0010] The state of the art structures are the silicon prints applied to the bottom of the socks in serigraph stencils. The mentioned silicon prints are directly applied on to the socks. Therefore it is not the genuine sole. Since the bottom surface is made of silicon, it is not possible to obtain the sufficient warming and this results in illnesses.
[0011] Another disadvantage is that the socks, which have silicon prints on the sole, have a shorter lifespan. Silicon print causes the socks to fall apart on the sides while washing. It doesn't hold well. Besides, silicon is a carcinogenic substance. It is harmful to health.
[0012] During the research related to the state of the art, an application with the title “Non-slip of Socks” and application no. JP05117902has been discovered. In this application, there is a non-slip layer on the sole of the socks formed in a pointwise manner. On the sole of the sock, a material with a high non-slip characteristic is used such as epoxy resin, urethane resin etc.
[0013] Another application discovered on the relevant technical field, regarding the state of the art, is the application no. FR2843686. In this application, there are protrusions on the bottom surface to obtain high adhesion on rough and wet surfaces. This application discloses a non-slip sock to be used especially on wet surfaces.
[0014] However, these applications do not mention any structures to eliminate the aforementioned disadvantages.
[0015] In conclusion, the existence of the problems above and insufficiency of the present solutions have necessitated making an improvement on the related technical field.
BRIEF SUMMARY OF THE INVENTION
[0016] The present invention relates to socks with non-slip soles developed in order to eliminate all disadvantages mentioned above and to provide new advantages in the related technical field.
[0017] An object of the socks with non-slip sole of the invention is to obtain socks with genuine non-slip soles by combining soft plastic, fabric, ethyl vinyl acetate (EVA) and preferably leather material.
[0018] Another object of the invention is to obtain socks that are cold proof due to their genuine non-slip sole.
[0019] Another object of the invention is to obtain long-lasting and washable non-slip socks.
[0020] Another object of the invention is to obtain semi-orthopedic socks.
[0021] Another object of the invention is to eliminate the disadvantages of the state of the art, occurring due to the use of silicon and to obtain carcinogen-free non-slip sole socks. In addition, ethyl vinyl acetate used on the non-slip sole does not produce bacteria. Therefore, a significantly healthy product is obtained.
[0022] The mentioned advantages are achieved by socks with non-slip sole containing soft plastic material, fabric material and ethyl vinyl acetate (EVA) positioned one after another respectively in the most general manner.
[0023] In another preferred embodiment of the invention, there is genuine or artificial leather material positioned on the mentioned ethyl vinyl acetate (EVA) of the mentioned non-slip sole.
[0024] In another preferred embodiment of the invention, the mentioned fabric material is felt.
[0025] The structural and characteristic properties and all advantages of the invention will be more clearly understood by the figures given below and detailed written description addressed to the figures. Therefore, the evaluation should also be done by taking into account these figures and detailed description.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0026] FIG. 1 is a perspective view of an alternative embodiment of the socks with non-slip soles of the present invention.
[0027] FIG. 2 is a view of an alternative embodiment of the socks with non-slip soles, showing the layers of the non-slip sole.
[0028] FIG. 3 is a view of the non-slip sole from below.
DESCRIPTION OF THE PART REFERENCES
[0029] 10 . Non-slip sole
[0030] 11 . Soft plastic material
[0031] 12 . Fabric material
[0032] 13 . Ethyl Vinyl Acetate (EVA)
[0033] 14 . Leather material
[0034] 20 . Sock
DETAILED DESCRIPTION OF THE INVENTION
[0035] In this detailed description, preferred embodiments of the socks with non-slip sole ( 20 ) of the invention are explained only for better understanding of the matter in a manner not to have any limiting effects.
[0036] FIG. 1 shows the perspective view of an embodiment of the socks ( 20 ) with non-slip soles ( 10 ) of the invention, and FIG. 2 shows the layers of the non-slip sole ( 10 ). The mentioned non-slip sole ( 10 ) is composed of, respectively from bottom to top, soft plastic material ( 11 ), fabric material ( 12 ), ethyl vinyl acetate ( 13 ) and preferably leather material ( 14 ) layers. The mentioned leather material ( 14 ) can be artificial or genuine leather optionally.
[0037] First of all, soft plastic material ( 11 ) is moulded according to foot structure and size. The material is then taken out of the mould after a sufficient amount of time, put into a baking oven and is hardened after it is heated and held at a certain temperature for a certain amount of time. Fabric material ( 12 ) is then placed on to the hardened soft plastic material ( 11 ). The mentioned fabric material ( 12 ) is preferably felt. Soft plastic material ( 11 ) and fabric material ( 12 ) are combined in a press machine and thus, the sole is formed. Then ethyl vinyl acetate ( 13 ) is placed on the mentioned sole. After this stage, optionally genuine/artificial leather material ( 14 ) is placed on EVA ( 13 ). Therefore, non-slip sole ( 10 ) is formed.
[0038] The non-slip sole ( 10 ) manufactured in foot shape, is then sewn on the sock ( 20 ). Thus, sock with non-slip sole ( 20 ) is obtained.
[0039] The mentioned soft plastic material ( 11 ) is one of the members or a combination of the members selected from the group containing: polyvinyl chloride (PVC), polyethylene (PE), high-density polyethylene (HDPE), cross-linked polyethylene (XLPE), thermoplastic, liquid crystal (Thermochormic), polybenzimidazole (PBI), thermoplastic polyurethane (TPU), vinyl polymer, thermoplastic elastomer (TPE), polyolefin (POE), polyisobutylene (PIB), ethylene-propylene rubber (EPR), ethylene-propylene-diene rubber (EPDM), polypropylene (PP), polybutylene (PB), natural rubber, silicone rubber, polyisoprene synthetic rubber, latex, polytetrafluoroethylene (PTFE), elastomer, thermoplastic rubber, liquid silicone rubber, polyurethane (PU), ethyl vinyl acetate (EVA), phthalate, bioplastic and biopolymer. | A sock is provided containing a non-slip sole connected to the bottom part. Specifically, the non-slip sole contains soft plastic material, fabric material, and ethyl vinyl acetate (EVA) layers placed on top of each other respectively. | 0 |
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to a harness which engages the fore end of a boat below the gunwale for docking.
2. Description of the Prior Art
Slips for docking boats are generally provided with pilings to which lines are tied to secure the boat within the slip. When docking, the boat must be carefully maneuvered into the slip and engines reversed to avoid colliding with the sides or end of the slip.
While experienced boaters usually can dock a boat in a slip without problem if a boater is not careful, serious damage to the boat or the dock may occur if the sides of the slip or endwall contact the boat.
The ideal connection between a boat and a slip is a flexible line which permits movement of the boat relative to the slip in controlled amounts as required to accommodate wave action. Bumpers attached to the dock or boat must be properly located to be effective and require frequent adjustment.
These and other problems encountered by the prior art are addressed by the invention as described below.
SUMMARY OF THE INVENTION
According to the present invention, a boat harness for guiding and guarding a boat bow when docking in a slip having fore, port and starboard mooring points is described. A port line is connected to the port mooring point, a starboard line is connected to the starboard mooring point and the port line at a junction point. A fore line connects the junction point to the fore mooring point and holds the port line and starboard line in a generally V-shaped configuration into which a boat may be guided for docking. The port and starboard lines center the boat bow relative to the junction point and hold it away from the sides of the slip.
According to another aspect of the present invention, lower port and starboard lines are similarly interconnected at a lower junction point. The lower port and starboard lines engage the boat bow at a location spaced from and below the port line and starboard line. The lower port and starboard lines function to spread the force of contact by the boat. The force of contact may also be spread by providing a flexible interconnection between the port and starboard lines and the lower port and starboard lines. The flexible member may consist of a plurality of lines extending transversely relative to the upper and lower port and starboard lines.
The port and starboard lines may be formed in a single integral piece, and the lower port and lower starboard lines may also be formed in a single piece.
A tubular sheath is preferably provided on both the upper line and the lower line at the junction point and lower junction point to protect the lines from wear.
The fore line preferably includes means for biasing the junction point toward the fore mooring point such as an elastic or spring member. The biasing means as well serves to support the port and starboard line above water level forward of the port and starboard mooring points. The spring may be a helical spring which is connected at its opposed ends to knotted spaced points on the fore line. Alternatively, the fore line may be formed in whole or in part by an elongated elastic segment which provides the desired biasing and supporting functions.
These and other objects and advantages of the invention will become more apparent upon review of the attached drawings in light of the detailed description of the drawings below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a boat with its bow engaging a boat harness of the present invention;
FIG. 2 is a plan view of the boat harness shown in FIG. 1 disassembled from the mooring points;
FIG. 3 is a fragmentary side elevational view of one line of the boat harness connected to a mooring point;
FIG. 4 is a perspective view of a line clamp used for securing one of the lines to a mooring point; and
FIG. 5 is a side elevational view of an alternative embodiment of the boat harness of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 and 2, the boat harness 10 of the present invention is illustrated. In FIG. 1, a boat 12 is shown docked in a slip 14 with the boat harness 10 of the present invention deployed.
The slip 14 may be an open slip as illustrated or could include one or more side walkways on the starboard and/or port side of the boat.
As used herein, the terms "fore", "port" and "starboard" are to be understood as to referring to the normal meaning of those terms as applied to the boat 12 docked in the slip 14.
The slip 14 is defined by a fore mooring point 16, port mooring point 18, and a starboard mooring point 20. On the port side of the boat 12, a port line 22 is tied to the port mooring point 18. A starboard line 24 on the starboard side of the boat 12 is secured to the starboard mooring point 20. A fore line 26 extends forwardly from the prow of the boat 12 and is secured to the fore mooring point 16. The port line 22, starboard line 24 and fore line 26 are joined at a junction point 28 and form a generally Y-shaped configuration with the "V" portion of the "Y" being made up of the port line 22 and the starboard line 24
Lower port line 30 and lower starboard line 32 are joined at a lower junction point 34 and hang below the port line 22 and starboard line 24.
In the preferred embodiment, the port line 22 and starboard line 24 form a continuous upper line 33 formed of one length of rope or strapping, and the lower port line 30 and lower starboard line 32 similarly form a continuous lower line 35 of one length of rope or strapping. The lower port line 30 and lower starboard line 32 are connected to the port line 22 and starboard line 24 by one or more flexible members such as a strap 36. An odd numbered plurality of straps 36 are preferably secured about the lower line 35 and the upper line 33. One of the straps 36 extends between the junction points 28,34. The other straps 36 are equally spaced along the upper and lower lines 33,35 between the port and starboard mooring points 18,20.
A ring 29 is preferably provided at the junction point 28. Ring 29 is connected by a strap 36 to junction point 28 and to the end of the fore line 26 opposite the fore mooring point 16.
The lower port and starboard lines 30 and 32 are preferably shorter than the port and starboard lines 22 and 24 so that they, and the lower junction point 34, are slightly aft of the junction point 28. As shown in FIG. 1, this accommodates the conventional bow shape below the gunwale which slopes rearwardly from the fore point to the keel. Ideally, the junction point 28 and lower junction point 34 would be contacted substantially simultaneously by the bow. If one line is contacted first it will tend to stretch until the second line is engaged. The dual line is intended to spread the force of the bow engaging the lines and add strength to the harness.
Tubular sheaths 38 which are lengths of flexible tubing are placed on the lines 22, 24, 30, 32 at the junction point 28 and the lower junction point 34. The tubing prevents frictional wear of the lines 22,24,30,32 caused by engagement with the boat 12. The tubular sheaths 38 may be replaced periodically.
The fore line 26 preferably biases the junction point 28 toward the fore mooring point 16. Means for biasing the junction point 28 may include a helical spring 40 connected to two knotted spaced points 41 on the fore line as shown in FIGS. 1 and 2. The helical spring 40 pulls the junction point 28 toward the fore mooring point and consequently holds the lines 22,24,30,32 in a substantially horizontally array above and substantially parallel to the water line. As the lines 22,24,30,32 stretch over time they can be periodically re-wrapped and secured to the mooring points 18,20. The helical spring 40 is intended to take up slack between adjustments.
Referring now to FIG. 4, a line clamp 42 is shown in detail. Line clamps 42 are shown attached to the boat harness 10 in FIGS. 1 and 2. The line clamp 42 secures a terminal end 44 of each of the lines 22,24,30,32 back to the line 22,24,30,32 after being wound about the mooring points several times. The line clamp 42 includes a tongue 46 which is received in a groove 48. The tongue 46 and groove 48 include cooperating complementary ridges 50 which hold the line clamp 42 together. Gripping ribs 52 are formed on the inner diameter of the line clamp 42.
Referring now to FIG. 3, the line may be secured to the mooring points by attachment to the terminal end 44 of each line 22,24,30,32 of an elastic cord 54 having a hook 56 which engages the line 22,24,30,32.
Referring now to FIG. 5, an alternative embodiment of the boat harness 10 is shown wherein an elastic fore line 58 is provided. The elastic fore line 58 would take the place of the fore line 26 and would eliminate the need for the helical spring 40. The upper and lower lines 33,35 are shown interconnected by a woven series of lines 60 which provide a broader area of contact with the boat 12.
After the boat is maneuvered into the boat harness 10 it can be tied off in the slip 14 with conventional lines both fore and aft. The boat harness 10 serves to center the fore end of the boat 12 in the slip 14.
It will be readily appreciated that the boat harness 10 of the present invention is easy to install in a slip and greatly simplifies docking a boat 12 in a slip 14 because the fore end of the boat 12 is automatically centered by the boat harness 10. The flexibility of the lines 22,24,30,32 permits limited movement of the boat 12 caused by wave action.
It will be readily appreciated that many modifications and variations of the boat harness of the present invention may be made without departing from the scope and spirit of the invention as defined by the following claims. | A harness for aligning and protecting the bow of a boat during docking. A starboard, port and fore line are joined at a junction point and connected to three spaced mooring points. Upper and lower starboard and port lines are flexibly interconnected. A spring biasing member is connected to the fore line for biasing the junction point of the port and starboard lines toward the fore line. Flexible tubing sections sheath the upper and lower lines adjacent the junction point. The fore, starboard and port lines are wrapped about their respective mooring points and secured by plastic clamps. | 4 |
FIELD OF THE INVENTION
This invention relates to the field of munitions, and particularly to land mines having military vehicles as their targets.
BACKGROUND OF THE INVENTION
It is known that the crossing of particular land areas by military vehicles can be interdicted by distributing a plurality of land mines in the area. Each mine is capable of independently fuzing upon the approach of military vehicles. Two types of such mines which operate on magnetic principles are known.
Mines of the passive type operate in the mangnetostatic mode: they sense the distortion of the earth's magnetic field by the approach of a vehicle, or they may sense any magnetization residual in the vehicle itself. They ordinarily have a ferromagnetic-core sensing mechanism to increase their sensitivity, and operate with very low battery drain and hence remain operative for extended periods. In addition, they are subject to countermeasure techniques, and also are triggered by vehicle side-passes at distances where the resulting discharge does not damage the vehicle and is thus wasted.
Mines of the active type operate by creating a local electromagnetic field and detecting distortion of that field caused by the approach of a vehicle. They are less subject to side pass difficulties and to countermeasures, but require so much energy that their batteries quickly discharge and the effective life of the mine is intolerably reduced.
A further desirable characteristic for land mines should be mentioned. For direct overpasses, a mine is more effective beneath the front axle and cab portion of a wheeled vehicle, but is more effective beneath the center of the tank: accordingly, it is desirable that a mine discharge at an optimum point in the overpass of a vehicle, depending on the nature of the vehicle.
BRIEF SUMMARY OF THE INVENTION
The present invention is a mine fuse design combining the advantages of passive and active modes to give munitions having low power demand, low cost, low false alarms, excellent target localization, side pass rejection, and counter measure resistance, and the possibility of discrimination between target types.
Various advantages and features of novelty which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and objects attained by its use, reference should be had to the drawing which forms a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing, FIG. 1 shows, in block diagram, a mine fusing circuit according to the invention, and FIGS. 2 to 8 inclusive show wave forms of significance in the operation of the munition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to FIG. 1, our mine fusing circuit 11 is shown to comprise a passive detector 12, an active detector 13, and signal processing logic 14.
Passive detector 12 includes an air-core coil 20 connected to a preamplifier 21 and then through a low-pass filter 22 to a post-amplifier 23, which supplies a first input 24 to logic 14. Filter 22 may have an upper cutoff frequency of less than 100 cycles per second. In logic 14 input 24 is supplied to a bipolar threshold detector 25 which controls a timer 26.
Members 21-26 are energized from a battery 27 as suggested by lead 28: they constitute a very small load on the battery, which accordingly has a long lite.
Coil 20 also forms a part of active detector 13, being connected as the inductor of a signal oscillator 30 operating in the frequency range of forty to sixty kilocycles: this frequency is, of course, not passed by filter 22 in passive detector 12. The signal from oscillator 30 is combined in a mixer 31 with the signal from a reference oscillator 32, to give an intermediate frequency output 33 which varies with the passing of a vehicle through the field. The intermediate frequency signal is fed through an intermediate frequency amplifier 34 to a phase-lock loop 35, the output of which is fed through a buffer amplifier 36 to comprise a second input 37 to logic 14.
Members 30-36, and the components of logic 14 about to be described, are energized from a second battery 40, as suggested by lead 41, when a switch 42 is closed. Closure of switch 42 is controlled by the output signal 43 of timer 26, so that unless passive detector 12 has supplied a proper output, active detector 13 is not energized and its relatively large load is not placed on battery 40. It will be realized that a single battery may be used instead of separate batteries, if this seems desirable.
Input 37 is supplied to a first differentiator 44, whose output 45 is supplied to a second threshold detector 46, to a second differentiator 47, and to a sample-and-hold circuit 50.
Detector 46 operates a second timer 51 giving an output 52. Outputs 52 and 43 are fed to a logical AND circuit 53 whose output 54 enables a counter 55.
Differentiator 47 supplies an output to a zero-crossing circuit 56 which in turn actuates counter 55 when the counter is enabled at 54. An output 57 from counter 55 is supplied as an input signal to a logical OR circuit 60. Another output 61 from counter 55 enables a second counter 62, and activates sample-and-hold circuit 50, the output of which is fed to a voltage controlled oscillator 63 to determine its frequency. The oscillator output drives counter 62 when the counter is enabled, and the counter output is fed to a further count threshold detector 64 which supplies a second signal 65 to OR circuit 60, which in turn supplies as its output 66 a "fire" signal for causing discharge of the mine.
OPERATION OF THE INVENTION
The operation of our invention will be best understood by referring to FIGS. 2-8 of the drawing.
FIG. 2 shows a typical "signature" or signal 70 at input 24 resulting from the overpass of a vehicle over a passive detector. The masses of magnetic material at various locations in the vehicle react with the earth's magnetic field to cause variations in the number of lines of magnetic flux cutting the coil as the vehicle passes, which results in an output of an irregular wave form as shown. This signature begins while the vehicle is still some little distance away, and continues until the vehicle has passed on by some little distance. There is no way to determine from this signature what sort of a vehicle is overpassing. This is not the case, however, for an active detector, where the typical signature 71 of a tank, as shown in FIG. 3 is recognizably different from the signature 72 of a wheeled vehicle, as shown in FIG. 4. Note that the first, second, and third axles of a wheeled vehicle are clearly evident in the active detector signature, while the flat bottom hull of a tank is equally clearly displayed.
It is also to be noted that the signature from an active detector does not begin until the vehicle is nearly directly over the detector: this is not the case with a passive detector. When both detectors are present, the signal of a passive detector will reach a satisfactory threshold level before the signature of an active detector begins to appear.
FIGS. 5-8 show the results of once and twice differentiating the signatures of FIGS. 3 and 4, and will be referred to below in more detail.
When it is desired to interdict the passage of vehicles through a particular area, the area is sown with land mines according to the invention. The mines may be buried, but they are not large and not readily observable to a vehicle operator, and can frequently be distributed on the surface of the area, where they remain operable until their batteries 27 run down or predetermined time out occurs. The mines are shaped so that the axes of the coils are substantially vertical. In the initial condition of the munition, passive detector 12 is energized, but switch 42 is open, so that there is no load on battery 40, and no energization of detector 13 or of the logic elements connected thereto. Counters 55 and 62 are at zero and are disabled. This condition continues until a vehicle approaches the mine closely enough that the output of post-amplifier 23 passes the thresholds of detector 25, lines 73 and 74 of FIG. 2. When this happens, timer 26 operates, supplying a signal 43, which closes switch 42 for a predetermined interval, and also for that interval comprises a first input to AND circuit 53 even if the signature should drop within the thresholds.
Note that system operation thus far could also result from a vehicle passing beside the munition rather than overpassing it, and could also result from vehicles equipped with magnetic countermeasures: under these alternate conditions, discharge of a passively operated mine would be a waste of the munition. Our arrangement is such therefore that signal 43 alone is not sufficient to discharge the mine. If no second signal is supplied, from active detector 13, within the time interval set by timer 26, signal 43 ceases, and the mine reverts to its initial condition unless a signal at 24 of magnitude greater than that of threshold detector 25 continues to be present.
Closure of switch 42 by detector 12 energizes detector 13 and its related logic elements: because of the relation between the passive and active signatures, this takes place before the active signature of an approaching vehicle begins to appear.
It is intended that when a passive detector signal is present, the mine discharges almost at once when an active detector signal due to a wheeled vehicle appears, but discharges only after a delay when an active detector signal due to a tank appears. The delay is to be generally proportional to the speed of the tank, which the apparatus also determines. System operation for a tank will be considered first.
The signal 71 of FIG. 3 is fed through differentiator 44 and appears at 45 with the general wave form 75 of FIG. 5 having single initial pulse 76. This signal is supplied to detector 46 and is of sufficient magnitude to exceed the threshold 77 of the detector and cause the detector to energize timer 51, which supplies for a second interval a second signal 52 to AND circuit 53. The AND circuit acts at 54 to enable counter 55. The output 45 of differentiator 44 is also supplied to second differentiator 47, which supplies to zero-crossing detector 56 a wave form 80 shown in FIG. 6 to have a single initial zero-crossing 81. Detector 56 supplies a single pulse to counter 55, which has been enabled, and which gives a "1" output 61 which functions to enable counter 62 and activate sample-and-hold circuit 50.
It is evident that the magnitude of pulse 76 in FIG. 5 at the zero crossing point 81 in FIG. 6 is determined by the speed of the moving vehicle. Circuit 50 supplies a signal determined by this magnitude to voltage controlled oscillator 63, to vary its frequency and hence to vary the rate at which pulses are supplied to counter 62, now enabled from counter 55. When the count from counter 62 reaches a predetermined number, as sensed by detector 64, it supplies a signal 65 to OR circuit 60. This signal has been delayed by the time required to reach the predetermined count at a rate determined by oscillator 63, and hence by the speed of the tank. After the delay, the firing signal is given at 66.
For a wheeled vehicle, operation is as follows. The signal 72 of FIG. 4 is fed through differentiator 44 and appears at 45 with the general wave form of 82 in FIG. 7 having a pair of initial pulses 83 and 84. This signal is supplied to detector 46 and the first pulse is of sufficient magnitude to exceed the threshold 77 of the detector and cause the detector to energize timer 51 as before, so that the timer supplies for the second interval a second signal to AND circuit 53, which acts at 54 to enable counter 55. The output 82 of differentiator 44 is also supplied to second differentiator 47, which supplies to zero-crossing detector a wave form 86 shown in FIG. 4 to have first and second zero-crossings 87 and 90. Detector 56 now supplies a pair of pulses to counter 55, which has been enabled, and gives a "two" output 57 which acts through OR circuit 60 to supply fire signal 66 at once. In this case, components 50, 63, 62, and 64 may operate but perform no function. In reaching its "two" output, counter 55 also gives a "one" output, but there is not time for this output to accomplish anything.
Numerous characteristics and advantages of the invention have been set forth in the foregoing description, together with details of the structure and function of the invention, and the novel features thereof are pointed out in the appended claims. The disclosure, however, is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts, within the principle of the invention, to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | In combination: an air core coil; a passive detector connected to said coil for giving a first output in response to change in the ambient magnetic field due to movement of a magnetic body near the coil; an active detector connected to the same coil and operable to create a local magnetic field about the coil and to give a second output in response to changes in the local field due to the movement of the body; apparatus energizing the active detector in response to the output of the passive detector; and apparatus giving a further output in response to simultaneous outputs from both the detectors. | 5 |
CROSS-REFERENCE TO RELATED U.S. APPLICATIONS
Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
Not Applicable.
REFERENCE TO AN APPENDIX SUBMITTED ON COMPACT DISC
Not Applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates, in general, to methods of tapering bristles for toothbrushes and toothbrushes having bristles manufactured using the methods. More particularly, the invention related to a method of tapering bristles for anchor-less toothbrushes and a anchor-less toothbrush which has bristles manufactured using the method.
2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98.
In conventional methods of manufacturing toothbrushes having tapered bristles, a bundle of bristles, each having an end point from 0.16 to 0.2 mm in diameter, is cut to a predetermined length. Thereafter, the end points of the bristles are hydrolyzed by an alkali chemical or strong acid chemical, thus being tapered. Subsequently, the bristles are washed in water and dried. The bristles are thereafter folded in half and set in holes, formed in a head part of a toothbrush body, using anchors.
Recently, toothbrushes have followed trends, so that various bristle setting patterns have been required. Furthermore, according to an increase in the size of a bundle of bristles, it has been difficult to set bristles using a conventional bristle setting machine and to fasten bristles with an anchor.
Three methods of manufacturing an anchor-less toothbrush are as follows.
First, as a method used by Coronet Co., Ltd. of Germany, bristles are set in a mold and, thereafter, resin is injected into the mold, thus integrating the bristles with a toothbrush body.
Second, as a method used the Oral-B company of U.S.A, bristles are set in a mold brush plate and, thereafter, the head insert having bristles is placed in a mold. Subsequently, resin is injected into the mold, thus fastening the bristles to a toothbrush body.
Third, as a method used the Boucherie company of Belgium which uses a bundle of bristles having a predetermined length, unlike other companies which use a spooled filament as a bristle. Bristles are set in a head insert made of plastic and, thereafter, the head insert is seated into a head insert seat formed in a head part of a toothbrush body. Subsequently, the head insert is bonded to the toothbrush body by ultrasonic waves.
The above-mentioned methods can reliably fasten bristles to a toothbrush body without anchor. However, the equipment is very expensive, and productivity is relatively low. Moreover, because a mold, a bristle setting machine and an injection molding machine are integrated together, it is very difficult to change the setting pattern of bristles.
However, toothbrushes manufactured by the above-mentioned methods can realize various bristle setting patterns. Thus, the appearance is superior. As well, the bristle setting pattern can freely be designed to match the tooth structure of every race. Therefore, toothbrushes manufactured by the above-mentioned methods have been popular among consumers.
In the toothbrushes manufactured by the above-mentioned methods, to realize various bristle setting patterns, the volume of a bundle of bristles must become large. As a result, it is impossible to taper bristles using a conventional physical grinding method. It is well known that if bristles are tapered, flexibility is increased so that the gums of a user are protected from injury while brushing the teeth, and penetration ability of the bristles is increased, thus enhancing tooth brushing efficiency.
In conventional anchor-less toothbrushes, because a spooled filament is typically used as bristles, it is difficult to taper bristles. Therefore, instead of a method of tapering bristles, bristles made of relatively flexible nylon, for example, nylon 6, 10, and nylon 6, 12 are used, thus overcoming the above-mentioned problems. However, a nylon bristle has insufficient durability and water resistance, compared with a polyester bristle. Also, because the penetration ability of bristles, which are not tapered, is poor, tooth brushing efficiency is reduced. Furthermore, bristles made of polyester cannot be used in such a toothbrush due to excessively high stiffness.
Due to these reasons, a tapering process is required even when manufacturing toothbrushes having various setting patterns. There are bristle tapering methods as follow. As described above, there is a method wherein a bundle of bristles is cut to a predetermined length and, thereafter, the ends of the bristles are hydrolyzed by an alkali chemical or strong acid chemical, thus being tapered. Subsequently, the bristles are washed in water and dried. Thereafter, the dried bristles are folded in half and set in a toothbrush body using anchors. There is a second method wherein bristles are tapered by a physical method such as a grinding method after a bristle setting process is conducted. There is a third method wherein bristles are partially tapered by the first method and then additionally machined by the second method.
However the second method is problematic because the length of tapered portions of the bristles is relatively short, such that the bristles are not sufficiently flexible. On the other hand, the third method has the advantages of solving the problem of the method the second method and reducing the manufacturing costs. This method was proposed in Korean Patent No. 261658 which was filed by the inventor of the present invention.
In addition, as proposed in Japanese Patent No. 3022762, there is a method wherein bristles are are immersed in an alkali chemical unit just before the cores of the bristles are dissolved, thus tapering ends of the bristles, after bristles are fastened to a toothbrush body using anchors made of metal, particularly, aluminum.
However, this method is problematic because the alkali chemical penetrates to the anchors due to a capillary phenomenon during the bristle immersion process. Thus, the anchors may be undesirably dissolved. If the anchors are dissolved, the set bristles may be removed from the toothbrush body. Furthermore, in the case of a mass production process, because hydrogen gas is generated when aluminum anchors react with alkali, there is the probability of the explosion of gas due to the heat in a reaction flask. Even if the material of the anchor is changed into brass, which has been popular, dissolution may occur because zinc, added to increase the stiffness of brass, react with alkali chemical.
Due to these reasons, a product manufactured by this method has been not commercialized. In consideration of economical efficiency, only products, which are manufactured by the method in which bristles are cut to predetermined lengths, both ends of the bristles are tapered using a chemical, and the bristles are folded in half and set in toothbrush bodies using anchors, have been commercialized.
Furthermore, in a toothbrush manufactured by this method, the thickness of an end point of each bristle is 50% or more than the thickness of the end point of the bristle before chemical-treating the bristle, and the tapered portion of the bristle is only about 3 mm. Therefore, penetration ability into gaps between teeth and flexibility are limited. To solve these problems, in Korean Patent No. 261658 which was filed by the inventor of the present invention, bristles are immersed in a chemical until just before the length of the bristles is reduced, thus being partially tapered. Thereafter, the bristles are set in a toothbrush body, and the bristles are ground by a grinder such that the diameter of an end of each bristle ranges from 0.04 mm to 0.08 mm. This method can solve problems of dissolution of an anchor and of a lack of penetration ability and flexibility.
However, the bristle tapering techniques, which are disclosed in the above-mentioned prior art, such as the conventional art proposed by the inventor of the present invention, have common problems. For example, the techniques cannot be applied to a toothbrush having variously shaped setting rows.
In an effort to overcome the above-mentioned problems, another technique was proposed in Korean Patent No. 3073200 which was filed by the inventor of the present invention. Unlike prior art using double-ended needle-shaped bristles, both ends of which are tapered, this technique uses single-ended needle-shaped bristles, only one end of which is tapered. The length of each single-ended needle-shaped bristle is half the length of the double-ended needle-shaped bristle. To manufacture a toothbrush, single-ended needle-shaped bristles are received in a receiving unit and are then inserted into a head insert, in which through holes having predetermined shapes are formed, by an insert rod of a pushing plate. Thereafter, portions of bristles protruding from a back surface of the head insert are thermally welded, thus fastening the bristles to the head insert. Subsequently, the head insert having the bristles is bonded to a toothbrush body. Alternatively, after the head insert is placed in a mold, an injection molding process is conducted, thus integrating the head insert with the toothbrush body.
In this technique, the bristles are reliably fastened to the toothbrush body without an anchor. Furthermore, because only one end of each bristle is tapered, the defective proportion is markedly low, thereby the manufacturing costs are also reduced. As well, this technique can manufacture toothbrushes having variously shaped setting rows.
However, there are problems as follows. As a first problem, in this technique, a bundle of bristles is cut to a length ranging from 15 to 20 mm and chemical-treated such that the length of tapered portions of bristles ranges from 4 to 8 mm and the thickness of end points of the bristles ranges from 0.01 to 0.03 mm. Thereafter, the bristles are tied with an elastic band after washing in water and drying them. Subsequently, the bristles are set in a bristle supply machine before a bristle setting process is conducted. At this time, some bristles may be broken due to their short lengths while removing the elastic band. Thus, the loss of bristles is increased. As a second problem, because the end point of the bristles have low thickness ranging from 0.01 to 0.03 mm, when the bristles are set in through holes of the head insert by the insert rod, the ends of the bristles may be undesirably bent. As a result, heights of the set bristles are uneven. As a third problem, the surface area of tapered bristles differs from the surface area of bristles which are not tapered. Accordingly, even for a skilled worker, much labor is required when setting the bristles in the toothbrush body.
BRIEF SUMMARY OF THE INVENTION
Accordingly, the present invention has been made keeping in mind the above problems occurring in the prior art, and an object of the present invention is to provide a toothbrush which has variously shaped setting rows and tapered bristles. Another object of the present invention is to provide a toothbrush which is manufactured by a simple manufacturing process. A further object of the present invention is to provide a toothbrush which has superior water resistance ability and durability, wherein bristles easily penetrate into gaps between teeth. Yet another object of the present invention is to provide a toothbrush manufacturing method which is able to reduce the defective proportion.
Technical Solution
In one aspect, the present invention provides a toothbrush manufacturing method including: setting bristles made of polyester into holes formed in a mold; injecting resin into the mold and forming a toothbrush body such that the bristles are integrated with the toothbrush body; and tapering ends of the bristles by immersing the bristles in a chemical.
In another aspect, the present invention provides a toothbrush manufacturing method, including: setting bristles made of polyester into a head insert; fastening the bristles to the head insert by thermally welding portions of the bristles, protruding from a back surface of the head insert, to the head insert; coupling the head insert, to which the bristles are fastened, to a toothbrush body; and tapering ends of the bristles by immersing the bristles in a chemical.
In a further aspect, the present invention provides a toothbrush manufacturing method, including: setting bristles made of polyester into a head insert; fastening the bristles to the head insert by thermally welding portions of the bristles, protruding from a back surface of the head insert, to the head insert; tapering ends of the bristles by immersing the bristles in a chemical; and coupling the head insert, to which the bristles are fastened, to a toothbrush body.
In yet another aspect, the present invention provides a toothbrush, including: bristles made of polyester and having end points from 0.01 to 0.03 mm in thickness and tapered parts from 4.0 to 10.0 mm in length. The bristles are set in a head part of a toothbrush without anchor. In the present invention, polyester means polyethylene terephthalate (PET), polybutylene terephthalate (PBT) or polytrimethylene terephthalate (PTT).
Advantageous Effects
In the present invention, the bristles can be securely set in a toothbrush body without an anchor. Furthermore, polyester bristles, which could not be set in toothbrushes having variously shaped setting rows due to excessively high stiffness, can be set in these types of toothbrush using the present invention. Particularly, the present invention can efficiently manufacture a toothbrush having variously shaped setting rows without expensive equipment.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a partial schematic view showing a conventional toothbrush body to which bristles are fastened by anchor.
FIG. 2 is a schematic view showing a toothbrush body having variously shaped setting rows.
FIG. 3 is a perspective view of a head insert to be used in the present invention.
FIG. 4 is a sectional view showing a process of setting bristles into a head insert, according to the present invention.
FIG. 5 is a sectional view showing the bristles fastened to the head insert by thermally welding parts of the bristles protruding from a back surface of the head insert, according to the present invention;
FIG. 6 is a perspective view showing the head insert in which bristles are set.
FIG. 7 is a perspective view of a holding jig to be used in the present invention.
FIG. 8 is a view showing a process of fastening the head insert having bristles to a toothbrush body according to the present invention.
FIG. 9 is a schematic view showing the head insert, to which bristles are fastened, placed in a mold according to the present invention.
FIG. 10 is a sectional view showing a process of integrating bristles, set in a mold, with a toothbrush body.
FIG. 11 is a view showing a pressure relief unit placed on the back surface of the head insert according to the present invention.
DESCRIPTION OF THE ELEMENTS IN THE DRAWINGS
1 : toothbrush body
10 : insert head
20 : holding jig
h: hole
S: receiving unit
u: head insert seat
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in detail with reference to the attached drawings.
FIG. 1 is a partial view showing a conventional toothbrush body to which bristles are fastened by anchors. In this case, bristles are set in holes (h) formed in a head part of the toothbrush body. In FIG. 1 , the diameter of a bundle of bristles ranges from 1.6 to 4.0 mm. In the case larger than the above-mentioned range, it is impossible to fasten bristles to the toothbrush body using an anchor.
FIG. 2 is a schematic view showing a toothbrush body which has variously shaped setting rows and is used for a toothbrush to be manufactured by a method in which bristles are thermally welded to a head insert 10 without an anchor, or in which the bristles are set in a mold. In this method, because a bundle of bristles is fastened to the toothbrush without an anchor, the size and shape are not limited to predetermined ranges. As such, because the size and shape are not limited to predetermined ranges, variously shaped setting holes (h) can be formed in the toothbrush.
The method of the present invention can be applied both to a method in which bristles are set in the head insert 10 and, thereafter, a head insert 10 is coupled to a toothbrush body 1 , and to a method in which bristles are set in a mold and, thereafter, resin is injected into the mold to form a toothbrush body 1 so that the bristles are integrated with the toothbrush body 1 .
The former method will be explained herein below.
FIG. 3 shows a head insert 10 to be used in the present invention. The head insert 10 has variously shaped setting holes (h) therein. Bristles are set in the setting holes (h). The end points of the bristles to be set may have the same thickness. Alternatively, the end points of the bristles may have different thicknesses. In the case of the bristles having end points different in thickness, there is an advantage of extension of the lifespan of a toothbrush.
Furthermore, polyester bristles along with bristles made of different material, for example, along with nylon bristles, may be set in the head insert 10 . In the case that bristles made of different materials are combined together, when the different bristles are immersed in a chemical to taper the bristles, some bristles may not be hydrolyzed. From this, the cleaning ability of the toothbrush may be appropriately adjusted. In detail, polyester bristles are hydrolyzed when being immersed in a chemical, thus having flexibility and penetration ability. On the other hand, bristles made of other material are not hydrolyzed, thus having high stiffness and cleaning ability. If such characteristic is appropriately adjusted, a toothbrush having desired properties can be obtained.
FIG. 4 is a sectional view showing a process of setting bristles into the head insert 10 . FIG. 5 is a sectional view showing the bristles fastened to the head insert 10 by thermally welding parts of the bristles protruding from a back surface of the head insert. The bristles are set in the head insert 10 such that portions of the bristles protrude from the back surface of the head insert by 1 to 3 mm. The portions of the bristles protruding from the back surface of the insert head are fastened to the head insert 10 by thermal welding. The head insert 10 to which the bristles are fastened is shown in FIG. 6 .
The bristles fastened to the head insert 10 are tapered by immersing end portions of the bristles in an acid or alkali chemical. Thereafter, the head insert 10 having the bristles is fastened to the toothbrush 1 . As a preferable immersion method, as shown in FIG. 7 , a holding jig 20 which holds the head insert 10 is used. The holding jig 20 has a receiving hole which has a size large enough to receive all bristles therein, but smaller than the head insert. The bristles are received in the receiving hole, and the head insert 10 is held by the holding jig 20 . When using the holding jig 20 to hold the head insert 10 , it is easy to immerse the bristles to desired lengths.
Here, the bristles may be completely tapered in the above-mentioned immersion process. Alternatively, after the bristles are partially tapered using the immersion process, an additional physical tapering process such as a grinding process may be executed. Regardless of a bristle tapering method, it is preferable that the bristles be tapered such that the thickness of the end points ranges from 0.01 to 0.07 mm and the length of the tapered portions ranges from 3 to 7 mm.
FIG. 8 is a view showing a process of fastening the head insert 10 , to which bristles are fastened, to a toothbrush body 1 . The head insert 10 is fastened to the toothbrush body 1 by inserting the head insert 10 into a head insert seat (u) formed in the toothbrush body 1 .
This method has advantages as follows. Because only the relatively small head insert 10 , to which bristles are fastened, is involved in a bristle tapering process, a large number of bristles is treated at one time, compared with a method in which bristles are directly set in a mold and, thereafter, the bristles are integrated with a toothbrush body by injecting resin into the mold. Furthermore, even when bristles are washed in water after conducting a process of immersing in a chemical, there is an advantage thanks to the small size. Also, because the back surface of the head insert 10 is exposed to the outside, the time required to wash the head insert 10 in water is reduced. In addition, when a defect occurs, only the head insert 10 is scrapped. The entire toothbrush is not scrapped. Consequently, the loss of products is reduced. Moreover, during the bristle tapering process, the toothbrush body is prevented from being contaminated. However, this method cannot be applied to a product to be manufactured by a method in which an entire toothbrush body 1 is simultaneously formed without a separate head part thereof.
As another method of fastening the head insert 10 to a toothbrush body 1 , there is a method in which the head insert 10 having bristles is placed in the mold and, thereafter, resin is injected into the mold. In this method, the head insert can be integrated with the toothbrush body without a separate bonding process. As required, a pressure relief unit (r) having a thin plate shape may be layered on the back surface of the head insert before the resin injection process (see, FIG. 11 ). The pressure relief unit (r) prevents resin from flowing out along the bristles due to injection pressure. FIG. 9 is a view showing the head insert 10 , to which bristles are fastened, placed in the mold.
Unlike the above-mentioned toothbrush manufacturing methods, a method, in which bristles are directly set in a mold and, thereafter, a toothbrush body is formed by injecting resin into the mold so that the bristles are integrated with the toothbrush body, is as follows.
After bristles are set in the mold in a shape shown in FIG. 10 , as disclosed in Korean Patent Laid-open Publication No. 2001-00341454, parts of the bristles protruding into a cavity of the mold are thermally welded so that bristle setting holes of the mold are sealed. Thereafter, resin is injected into the cavity of the mold. At this time, the pressure of the cavity of the mold is sensed to prevent resin from leaking out along the bristles through the bristle setting holes of the mold. If the pressure of the cavity is greater than a preset value, the resin injection is temporarily stopped. When the pressure of the cavity is returned to the normal value, the resin injection resumes. By such a method, the bristles set in the mold are integrated with the toothbrush body.
The bristles of the toothbrush, which is manufactured using the above-mentioned method, are immersed in a chemical and are thus tapered in the same manner as that described for the toothbrush manufacturing method using the head insert 10 .
In the toothbrush manufacturing methods described above, as required, bristles may be intentionally unevenly set in a toothbrush body such that the lengths of exposed portions of the bristles differ from each other within a range from 1 to 10 mm.
Several examples of methods of manufacturing toothbrushes are as follows.
Example 1
Bristles, which have end points of 0.19 mm in thickness and are made of PTT, are set in a mold mounted to an AFT CNC machine which was produced by Boucherie Company of Belgium. Thereafter, portions of the bristles protruding into a cavity of the mold are thermally welded, and resin is injected into the cavity of the mold, thus manufacturing a toothbrush such that the bristles are integrated with a toothbrush body.
The manufactured toothbrush is fastened to a holding jig similar to that shown in FIG. 7 and is then immersed for 17 minutes in a reaction flask in which 35% sodium hydroxide solution is maintained at 120° C. Subsequently, the toothbrush is washed in water, neutralized and dried so that the toothbrush having tapered bristles is obtained. As a result, the thicknesses of the end points of the bristles range from 0.01 to 0.02 mm. The lengths of the tapered portions of the bristles range from 5 to 7 mm.
Example 2
A head insert, to which anti-bacterial bristles, which have end points of 0.18 mm in thickness, are made of PBT, and are manufactured by Kanebo Company of Japan, is manufactured, similar to the head insert of FIG. 6 , using the machine used in the first example. This head insert is treated through the same bristle tapering process as that of the first example. As a result, the thicknesses of the end points of the bristles range from 0.01 to 0.03 mm. The lengths of the tapered portions of the bristles range from 4 to 6 mm.
The manufactured head insert having bristles is seated into a bristle seat formed in a head part of a toothbrush body and is then bonded to the head part using ultrasonic waves, thus a toothbrush is obtained.
Example 3
A spooled filament, which has end points of 0.203 mm (8 mils) in thickness and is made of PBT, is continuously supplied to a weld-type toothbrush manufacturing machine which was made by Coronet Co., Ltd. of Germany, thus manufacturing a toothbrush in which bristles are set.
The manufactured toothbrush is fastened to a holding jig similar to that shown in FIG. 7 and is then immersed for 10 minutes in a reaction flask in which 95% sulfuric acid solution is maintained at 135° C., thus tapering the bristles. Subsequently, the toothbrush is washed in water, neutralized and dried. As a result, the thicknesses of the end points of the bristles range from 0.01 to 0.04 mm. The lengths of the tapered portions of the bristles range from 4 to 6 mm.
Example 4
Three kinds of bristles, which have end points of 0.152 mm, 0.178 mm and 0.203 mm in thickness and made of PBT and polyester elastomer mixed in a weight ratio of 7:3, are set in a head insert, made of plastic, by the machine used in the first example. Here, the bristles having end points of 0.152 mm in thickness are set in a central portion of the head insert. The bristles having end points of 0.178 mm in thickness are set in an intermediate portion of the head part. The bristles having end points of 0.203 mm in thickness are set in an edge portion of the head insert.
The manufactured head insert is fastened to the holding jig of FIG. 7 and is then immersed for 10 minutes in a reaction flask in which 98% sulfuric acid solution is maintained at 115° C. Subsequently, the head insert is washed in water, neutralized and dried, so that a toothbrush having tapered bristles is obtained. As a result, the thicknesses of the end points of the bristles range from 0.01 to 0.04 mm. The lengths of the tapered portions of the bristles range from 5 to 7 mm.
Example 5
Anti-bacterial bristles of Kanebo Company of Japan, which have end points of 0.18 mm in thickness and are made of PBT, and nylon bristles, which have end points of 0.20 mm in thickness, are combined in a ratio of 1:1. The time to immerse the bristles in a chemical is changed to 12 minutes. Other conditions are the same as those of the second example. In the above-mentioned conditions, a toothbrush is manufactured through the same process as that of the second example.
As a result, the thicknesses of the end points of the PBT bristles range from 0.03 to 0.05 mm, and the thicknesses of the end points of the nylon bristles are 0.20 mm.
Thereafter, the bristles are ground for 10 seconds using a drum grinder having protrusions for 10 seconds. As a result, bristles, which have end points from 0.01 to 0.02 mm in thickness and tapered parts from 3 to 5 mm in length, and bristles, which have end points from 0.10 to 0.15 mm in thickness and tapered parts from 1 to 2 mm in length, are combined together. | The present invention provides a method of tapering bristles for toothbrushes and a toothbrush having bristles manufactured using the method. One method disclosed in the present invention includes setting bristles made of polyester in a head insert, and fastening the bristles to the head insert by thermally welding portions of the bristles, protruding from a back surface of the head insert, to the head insert. The method further includes coupling the head insert to a toothbrush body and tapering ends of the bristles by immersing the bristles in a chemical. The bristles can be securely set in the toothbrush body without an anchor. Furthermore, polyester bristles, which could not be set in toothbrushes having variously shaped setting rows due to excessively high stiffness, can be set in these types of toothbrush by the toothbrush manufacturing method of the present invention. | 0 |
This application claims priority to provisional application No. 60/969,066 that was filed on Aug. 30, 2007.
TECHNICAL FIELD
The present application relates generally to the field of artificial lifts, and more specifically to artificial lifts in connection with hydrocarbon wells, and more specifically, associated downhole oil/water separation methods and devices.
BACKGROUND
Oil well production can involve pumping a well fluid that is part oil and part water, i.e., an oil/water mixture. As an oil well becomes depleted of oil, a greater percentage of water is present and subsequently produced to the surface. The “produced” water often accounts for at least 80 to 90 percent of a total produced well fluid volume, thereby creating significant operational issues. For example, the produced water may require treatment and/or re-injection into a subterranean reservoir in order to dispose of the water and to help maintain reservoir pressure. Also, treating and disposing produced water can become quite costly.
One way to address those issues is through employment of a downhole device to separate oil/water and re-inject the separated water, thereby minimizing production of unwanted water to surface. Reducing water produced to surface can allow reduction of required pump power, reduction of hydraulic losses, and simplification of surface equipment. Further, many of the costs associated with water treatment are reduced or eliminated.
However, successfully separating oil/water downhole and re-injecting the water is a relatively involved and sensitive process with many variables and factors that affect the efficiency and feasibility of such an operation. For example, the oil/water ratio can vary from well to well and can change significantly over the life of the well. Further, over time the required injection pressure for the separated water can tend to increase.
Given that, the present application discloses a number of embodiments relating to those issues.
SUMMARY
An embodiment is directed to a downhole device comprising an electric submersible motor; a pump connected with the electric submersible motor, the pump having an intake and an outlet; the electric submersible motor and the pump extending together in a longitudinal direction; an oil/water separating device having an inlet in fluid communication with the pump outlet and having a first outlet and a second outlet, the first outlet connecting with a first conduit and the second outlet connecting with a second conduit; a redirector integrated with the first conduit and the second conduit, the redirector having a flow-restrictor pocket that extends in the longitudinal direction, a downhole end of the flow-restrictor pocket connecting with a re-injection conduit; the first conduit extending uphole to a level of the flow-restrictor pocket, and the second conduit extending farther uphole than the first conduit; the uphole end of the flow-restrictor pocket connecting with the second conduit; and a passage connecting the first conduit with the flow-restrictor pocket.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a configuration of an embodiment;
FIG. 2 shows a portion of a cross section of an embodiment;
FIG. 3 shows a portion of a cross section of an embodiment;
FIG. 4 shows a portion of a cross section of an embodiment;
FIG. 5 shows a configuration of an embodiment;
FIG. 6 shows a cross section of a portion of an embodiment;
FIG. 7 shows a cross section of portion of an embodiment;
FIG. 8 shows a cross section of a portion of an embodiment; and
FIG. 9 shows a cross section of a portion of an embodiment in use.
DETAILED DESCRIPTION
In the following description, numerous details are set forth to provide an understanding of the present invention. However, those skilled in the art will understand that the present invention may be practiced without many of these details and that numerous variations or modifications from the described embodiments may be possible.
In the specification and appended claims: the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via another element”; and the term “set” is used to mean “one element” or “more than one element”. As used herein, the terms “up” and “down”, “upper” and “lower”, “upwardly” and downwardly”, “upstream” and “downstream”; “above” and “below”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly described some embodiments of the invention. However, when applied to equipment and methods for use in wells that are deviated or horizontal, such terms may refer to a left to right, right to left, or other relationship as appropriate.
The present application relates to downhole oil/water separation, and more particularly, advantageously managing back-pressure to manipulate the oil/water separation. One way to advantageously control separation of fluids is by regulating back-pressure applied to the oil stream and/or the water stream. One way to regulate back-pressure is by regulating a flow-restriction (i.e., throttling) of the oil stream and/or the water stream exiting the oil/water separator. Embodiments herein relate to equipment that allows a stream to be throttled, i.e., a back-pressure to be manipulated. The magnitude of a throttling can cover a range from completely closed to wide open depending on the oil/water content of the well fluid.
The form and function controlling backpressure and related flow is highly dependent upon the injection zone orientation relative to the producing zone (injection zone uphole or downhole of the producing zone). Some key differences between the two orientations relate to injecting uphole where the device can throttle and vent to a tubing annulus in a single operation, and injecting downhole where the device may need to throttle the flow “in-line”, .i.e. receive the injection flow from the tubing, throttle the flow, and then return the flow to another tube headed toward the injection zone. Some or all of these factors can be considered. The diameter of a throttle opening can generally be from 0.125 to 1.0 inches.
FIG. 1 shows an overall schematic for an embodiment of a device. Some of the main components of the device are an ESP 100 comprising a motor 110 and a pump 120 . A centrifugal or cyclone oil/water separator 200 is connected adjacent to the pump 120 . The apparatus is placed downhole in a hydrocarbon well, preferably inside a well casing 10 . The motor 110 drives the pump 120 . The motor 110 also drives the oil/water separator 200 . During operation, well fluid is drawn into the pump 120 through a vent 125 . The oil/water mixture is driven out of the pump 120 and into the oil/water separator 200 , a centrifugal type separator in this case. The oil/water separator 200 accelerates and drives the oil/water mixture in a circular path, thereby utilizing centrifugal forces to locate more dense fluids (e.g., water) to a farther out radial position and less dense fluids (e.g., oil) to a position nearer to the center of rotation. An oil stream and a water stream exit the oil/water separator 200 and travel separately along different paths to a redirector 250 , where the water stream is redirected and re-injected into formation while the oil stream is directed uphole to surface.
FIG. 2 shows a cut away view of the oil/water separator 200 , which is of the centrifugal type. A well fluid mixture is driven into and rotated in a cyclone chamber 201 of the oil/water separator 200 . The layers of the stream are separated by a divider 202 that defines a beginning of an oil conduit 204 and a beginning of a water conduit 206 . The oil conduit 204 is further inward in a radial direction with respect to the water conduit 206 . Back-pressure of the streams affects the oil/water separation process. For example, for well fluids having a high percentage of oil, higher back-pressure for the water stream 206 can improve separation results. Similarly, for well fluids having a higher percentage of water, a higher back-pressure for the oil stream 204 can improve oil/water separation. Essentially the same back-pressure principal applies to cyclone type oil/water separators.
FIG. 3 shows another sectional view of the oil/water separator 200 having the oil conduit 204 and the water conduit 206 . Arrows 350 show a representative path of the oil stream. Arrows 355 show a representative path of the water stream. A flow-restrictor 304 , e.g., a throttle, is in the water conduit 206 . The water stream flows uphole into the flow-restrictor 304 . The flow-restrictor 304 could be located in the oil conduit 204 . One flow-restrictor 304 could be in the water conduit 206 and another flow-restrictor 304 could be in the oil conduit 206 simultaneously. Selection of a flow-restrictor 304 from a number of different flow-restrictors having different variations of orifice size and configuration enables adjustment of the aforementioned backpressure in the water stream 206 . There are many ways to replace the flow-restrictor 304 with another different flow-restrictor 304 having a different throttle, thereby adjusting the backpressure situation. Preferably, a wireline tool can be lowered to place/remove a flow-restrictor 304 . A flow-restrictor 304 can also be inserted and removed using slickline, coiled tubing, or any other applicable conveyance method. Slickline tends to be the most economical choice. In connection with use of a slickline, or coiled tubing for that matter, the oil stream channel is preferably positioned/configured to prevent tools lowered down by wireline, slickline or coiled tubing from inadvertently entering the oil conduit 204 . The oil conduit 204 can be angled to prevent the tool from entering the oil conduit 204 . The oil conduit 204 can further be sized such that the tool will not be accepted into the bore.
Alternately, the flow-restrictor 304 can have a variable size throttle orifice so that replacement of the flow-restrictor is not required to vary orifice size. The orifice size can be varied mechanically in many ways, e.g., at surface by hand, by a wireline tool, a slickline tool, a coil tubing tool, a hydraulic line from the surface, by an electric motor controlled by electrical signals from the surface or from wireless signals from the surface, or by an electrical motor receiving signals from a controller downhole.
Check valves 302 can be located in the oil conduit 204 and/or the water conduit 206 . The check valves 302 can prevent fluid from moving from the oil conduit 204 and the water conduit 206 down into the oil/water separator 200 , thereby causing damage to the device.
Packers can be used to isolate parts of the apparatus within the wellbore. For example, FIG. 1 shows packers 410 and 420 isolating an area where water is to be re-injected into the formation from an area where well fluid is drawn from the formation. The packer configuration effectively isolates the pump intake from re-injection fluid. Alternately, the packer 420 could be located below the pump 200 , so long as the water is re-injected above the packer 410 or below the packer 420 , thereby adequately isolating the area where the well fluids are produced from the area of the formation where water is re-injected. No specific packer configuration is required, so long as isolation between producing fluid and injecting fluid is adequately achieved.
The above noted configurations can also be used to inject stimulation treatments downhole. FIG. 4 shows the apparatus of FIG. 3 except with the flow-restrictor 304 removed. FIG. 4 shows pumping of stimulating treatments down the completion tubing and into both the oil conduit 204 and the water conduit 206 . A flow-restrictor can be replaced with a flow device that prevents treatment fluid from following along the path of re-injection water. The arrows 360 illustrate a representative path of the stimulating treatment. The check valves 302 can prevent the stimulation fluid from traveling into the oil/water separation 200 , thereby potentially causing detrimental effects.
FIG. 5 shows a configuration to re-inject a water stream to a zone located below the producing zone. A motor 110 , a pump 120 , and an oil/water separator 200 are connected as before. A redirector 250 is connected uphole from the oil/water separator 200 . The redirector 250 is connected to a conduit 260 that extends downhole from the re-injection and through a packer 420 . The packer 420 separates a production area that is uphole from the packer 420 , from a re-injection area that is downhole from the packer 420 . In that embodiment, the water stream travels through a tailpipe assembly 270 . The tailpipe assembly 270 extends though the packer 420 into the re-injection area that is downhole from the packer 420 .
FIG. 6 shows a more detailed cross section of an embodiment of the redirector 250 . FIG. 9 shows a cross section of a redirector 250 and a flow-restrictor 304 in operation with the flow-restrictor 304 positioned in the flow-restrictor pocket 610 . The flow-restrictor pocket 610 is configured to receive a flow-restrictor 304 . The water conduit 206 is configured to be radially outside the oil conduit 204 , i.e., a centrifugal oil/water separation. The oil conduit 204 extends from down-hole of the redirector 250 , through the redirector 250 , and uphole past the redirector 250 , where the oil conduit 204 connects with production tubing 620 (e.g., coil tubing). The water conduit 204 extends from below the redirector 250 and into the redirector 205 . The water conduit 204 merges into a water passage 630 that connects the water conduit 204 with the flow-restrictor pocket 610 . The water passage 630 can extend in a direction substantially perpendicular to the water conduit 204 proximate to the water passage. That is, during operation, the flow of the water makes approximately a 90 degree turn. The water can alternately make as little as approximately a 45 degree turn and as much as approximately a 135 degree turn. A re-injection passage 670 extends from the flow-restrictor pocket 610 downhole past the redirector 250 . The re-injection passage 670 can be connected with completion tubing or other tubing.
FIG. 7 shows an embodiment of the flow-restrictor 304 . The flow-restrictor 304 has a body 701 that defines therein an upper inner chamber 725 and a lower inner chamber 720 . The upper inner chamber 725 and the lower inner chamber 720 are divided by a flow-restriction orifice 740 . The flow-restriction orifice 740 and the body 701 can be the same part, or two separate parts fit together. Preferably the flow-restriction orifice 740 has a narrower diameter in a longitudinal axial direction than either the upper inner chamber 725 or the lower inner chamber 720 . However, the diameter of the flow-restriction orifice 740 can be essentially the same diameter of either the upper inner chamber 725 or the lower inner chamber 720 . Passages 710 are located in the body 701 and hydraulically connect the upper inner chamber 725 with an outside of the flow-restrictor 304 . Passage 715 is on the downhole end of the flow-restrictor 304 . When the flow-restrictor 304 is in position in the flow-restrictor pocket 610 , the passages 710 allow fluid to pass from the water passage 630 , though the passages 710 and into the upper inner chamber 725 . The fluid then flows through the restrictor orifice 740 , into the lower inner chamber 720 and out of the flow-restrictor 304 for re-injection. It should be noted that the flow-restrictor 304 can have many internal configurations, so long as the flow is adequately restricted/throttled.
The flow-restrictor 304 has an attachment part 702 that is used to connect to a downhole tool (not shown) to place and remove the flow-restrictor 304 from the flow-restrictor pocket 610 . As noted earlier, the downhole tool can be connected to any relay apparatus, e.g., wireline, slickline, or coiled tubing.
There are many ways to determine an oil/water content of a well fluid. Well fluid can be delivered to surface where a determination can be made. Alternately, a sensor can be located downhole to determine the oil/water ratio in the well fluid. That determination can be transmitted uphole in many ways, e.g., electrical signals over a wire, fiber-optic signals, radio signals, acoustic signals, etc. Alternately, the signals can be sent to a processor downhole, the processor instructing a motor to set a certain orifice size for the flow-restrictor 304 based on those signals. The sensor can be located downstream from the well fluid intake of the oil/water separator, inside the oil/water separator, inside the redirector, inside the flow-restrictor, upstream of the oil/water separator, outside the downhole device and downhole of the well fluid intake, outside the downhole device and uphole of the sell fluid intake, or outside the downhole device and at the level of the well fluid intake.
One embodiment shown in FIG. 8 has a flow-restrictor 304 having a sensor 800 located in the upper inner chamber 725 . The sensor could be in the lower inner chamber 720 . The sensor 800 can sense temperature, flow rare, pressure, viscosity, or oil/water ratio. The sensor 800 can communicate by way of a telemetry pickup 810 that is integrated with the redirector 250 . The sensor 800 can communicate through an electrical contact or “short-hop” telemetry with a data gathering system (not shown).
The preceding description refers to certain embodiments and is not meant to limit the scope of the invention. | A downhole device having an oil/water separator having a well fluid inlet, an oil stream outlet conduit, and a water stream outlet conduit; a removable flow-restrictor located in at least one of the water stream outlet conduit or the oil stream outlet conduit. | 4 |
FIELD OF THE INVENTION
The present invention relates to systems, devices and methods for monitoring and controlling the electrical load and ambient temperature of electrical joints and electrical conductors in electrical circuits.
BACKGROUND OF THE INVENTION
Electrical joints in an electrical circuit are internationally recognized as one of the major causes of electrical failures in the electrical circuit. At the electrical loads associated with commercial use, failures of such electrical joints often results in an arc flash.
The arc flash causes an explosion which may result in a serious if not fatal injury to any person in close proximity to the compromised electrical joint when it fails. Furthermore, severe damage will be caused to the electrical equipment itself and there will be a loss of power to the affected circuits.
Thus the failure of an electrical joint can have serious economic, environmental and safety consequences. This is particularly applicable in organisations which have high downtime costs such as data centres, oil and gas production, refining and other high value large scale manufacturing sites.
The issue of electrical joint failure is so serious that commercial insurers often mandate the client to undertake annual inspections of their electrical equipment in general and particularly any mission critical electrical equipment which may result in the cessation of the business or for business to be severely interrupted should it fail.
The electrical joints may be, for example, joints between two sections of metal conductors, which are typically formed from copper or aluminium, or at the termination of a section of an electrical cable to a metal conductor.
At present the only way to detect if the integrity of an electrical joint has been compromised is to detect excess heat at the electrical joint. There are currently two methods used to detect such compromised joints.
The first method is periodic inspection of the electrical joints using a thermal imaging camera. Such inspections will be carried out whilst the electrical circuit and thus the electrical joint is energised with typically 50% or less of electrical load designed for the electrical circuit and thus the electrical joint. Depending on the particular country and the regulations in force the energised joints may or may not be exposed during the inspection. When the joints are not exposed the inspection is carried out externally, sometimes using a thermal window to enhance the level of infrared radiation visible to the thermal imaging camera.
The problem is that such inspections are often only carried out annually, i.e. 1 day out of 365, less than 1% of the operating time of the electrical circuit. As such any problems which develop with the electrical joints, to cause them to become compromised, may go unnoticed for a long period of time. Furthermore if the inspection is carried out externally a calculated correlation of the external temperature to the internal temperature of the electrical joint will need to be carried out. Given the number of variables at each location, the correlation is subject to errors, which may be large. In addition as such inspections are carried out at unknown or low electrical loads, i.e. below 50%, the inspection is often unable to determine that an electrical joint is compromised.
The second method is a more recent technology which enables thermal measurement of the joint to be carried out using passive thermal sensing devices which are located inside the electrical enclosure in which the electrical joint is housed to directly and continuously monitor the electrical joint. The thermal sensing devices measure the ambient temperature of the air in the enclosure in which the electrical joint resides, and the temperature of the electrical joint to calculate the temperature differential of the electrical joint, known as the ΔT value.
The temperature of the electrical joint uses a sensor which is typically either an infrared sensor located a short distance from the electrical joint which either measures the temperature of the electrical joint itself or the temperature of the electrical conductor adjacent the electrical joint, or a cable sensor which is mounted directly onto cable conductors adjacent the electrical joint. Other sensing devices may be used provided that they measure the temperature at the electrical joint itself or of the conductor adjacent to the electrical joint.
There are problems with both of these methods in that whilst it is theoretically possible to subsequently identify the electrical load that was applied to the electrical circuit on which a given electrical joint is located, and then correlate this with the ΔT value from the thermal inspection to determine whether or not a joint is compromised, this is not always so simple in practice.
In an organisation with many electrical circuits, and thus electrical joints, this process would be very time consuming, and thus unlikely to be commercially viable.
Furthermore thermal inspection reports are not typically integrated with computer building management systems, thus data would need to be collected from a number of sources which may have different time stamps, therefore such calculations are not always reliable, nor can they dynamically predict how much additional load can be safely applied to an electrical circuit which is at a low electrical load, i.e. the maximum safe operating capacity, at any given time.
The determination of how much extra electrical load can be safely added to an electrical joint in an electrical circuit is particularly important in organisations which operate systems with dual electrical feeds. Quite often an electrical feed will be shut down for periodic maintenance. This results in both electrical feeds being fed into a single feed. Thus, where both feeds originally operated at 30% electrical load, a single feed is now operating at 60% electrical load.
Such sudden increases in electrical load often result in a compromised electrical joint failing, as whilst the compromised electrical joint could cope with 30% electrical load, the compromised electrical joint could not cope with 60% electrical load. Neither periodic thermal inspection nor continuous monitoring would have been able to detect that such an electrical joint was compromised at low electrical load levels.
A further problem is that electrical circuits, and thus electrical joints normally have designated maximum operating temperatures imposed by the manufacturers, i.e. the maximum temperature at which they can be safely operated. Furthermore, there may be other maximum operating temperatures imposed by industry standard organisations such as UL, IEC and ANSI. However, this temperature is affected by both the electrical load being applied to the electrical joint and the local ambient temperature.
Thus if the local ambient temperature is high it may be necessary to reduce the electrical load passing through the electrical joint to ensure that the maximum safe operating temperature is not exceeded.
For example;
The maximum temperature at which an electrical joint can be operated at 100% load is dependent on the particular standards being adhered, i.e. British Standards, UL, IEC or ANSI standards. These standards stipulate a maximum rise of 50° C. above a 24 hour mean ambient temperature of up to 35° C. with an absolute maximum of 85° C., and peak ambient temperature of 40° C. with an absolute maximum of 90° C. ANSI alternatively permits a temperature rise of 65° C. above a maximum ambient temperature of 40° C. with an absolute maximum of 105° C. provided that silver plated terminations (or acceptable alternative) are provided in the electrical joint, if not then a maximum temperature rise of 30° C. is allowable with an absolute maximum of 70° C. For example, a manufacturer would have used these standards to calculate that the maximum ambient temperature that a particular electrical joint can operate at 100% electrical load is 50° C., as the ΔT value for the joint is 65° C. Thus if the ambient temperature rises to 60° C. the maximum load that the electrical joint could be used with safely is that which gives a ΔT of 55° C.
There is currently no system which enables effective monitoring of ambient temperatures and ΔT values of an electrical joint or an electrical conductor assuming the electrical joint is not compromised to indicate the maximum electrical load which can be passed though the given electrical joint or electrical conductor at a given ambient temperature.
SUMMARY OF THE INVENTION
The present invention relates to a method of continuously predicting in real time when an electrical joint in an electrical circuit is compromised at a low electrical load. The present invention also relates to a method of continuously predicting in real time the maximum electrical load which can be passed through a compromised electrical joint in an electrical circuit, i.e. the maximum safe operating capacity of the electrical circuit. The present invention also relates to a method of continuously calculating the temperature differential alarm threshold in real time throughout the full range of electrical loads, i.e. from 0-100%, for a given electrical joint in an electrical circuit. The present invention also relates to a method of continuously predicting in real time the maximum electrical load that can be passed through an electrical circuit at the ambient temperature within which the electrical circuit resides. The present invention also relates to a method of predicting by how much the ambient temperature must be reduced in order to operate the circuit at up to 100% load. This provides the ability for the OEM's to incorporate this invention into their products to have intelligent electrical enclosures which can operate at maximum safe loads. This also provides the ability for the invention to be retrofitted into existing electrical systems.
According to a first aspect of the present invention there is provided a load calculation device for determining the maximum electrical load that can be applied to an electrical circuit comprising:
a. means for determining the temperature differential (ΔT) between a section of the electrical circuit and the ambient air temperature in which the section of the electrical circuit resides; b. means for determining the actual electrical load applied to the electrical circuit; c. means for determining the design load of the electrical circuit; d. means for calculating the maximum electrical load that can be applied to the electrical circuit based on the temperature differential and the electrical load applied to the electrical circuit.
Preferably the values are continuously determined by the load calculation device in real time. This means that the values are determined every 0.5 to 30 seconds.
Preferably the load calculation device is adapted to continuously calculate the maximum electrical load that can be applied to the electrical circuit is calculated in real time. This means that the values are calculated every 0.5 to 30 seconds.
Preferably the means for determining the temperature differential comprises receiving the temperature of the section of the electrical circuit from a first sensing element and receiving the temperature of the ambient air in which the electrical circuit resides from a second sensing element.
The sensing elements may be for example:
A combined sensing element located close to the electrical joint which has a first sensing element which measures the temperature of the electrical joint or the temperature of the electrical conductor adjacent the electrical joint using non contact infrared for example, or a contact device such as a thermocouple or a fibre optic sensing device, and a second sensing element which measures the ambient air temperature within the enclosure. In one alternative such a combined sensing element sends each measurement separately to the local calculation device. In an alternative such a combined sensing element is provided with a device adapted to determine the ΔT value of the electrical joint or of the conductor adjacent the electrical joint which is effectively the ΔT value of the joint and the combined sensing element sends the ΔT value to the local calculation device. Separate contact or non contact sensing elements, the first sensing element located above the electrical joint which measures the temperature of the electrical joint or the temperature of the electrical conductor adjacent the electrical joint using infrared for example, and the second sensing element located remote from the first sensing element but still within the enclosure which measures the ambient air temperature within the enclosure. The load calculation device would then determine the ΔT value based on the individual temperature values. Separate linked elements, the first sensing element is located near or on the external insulating layer of an electrical conductor, in the case of an electrical cable, adjacent to the electrical joint which measures the temperature of the electrical conductor adjacent to the electrical joint which is connected to the second sensing element located remote from the first sensing element but still within the enclosure which measures the ambient air temperature within the enclosure wherein the second sensing element is provided with a device adapted to determine the ΔT value of the electrical conductor adjacent to the electrical joint which is effectively the ΔT value of the electrical joint which then sends the ΔT value to the load calculation device.
Preferably the section of the electrical circuit comprises an electrical joint.
Preferably the load calculation device further comprises means for determining the maximum temperature differential allowed.
According to a second aspect of the present invention the maximum electrical load that can be applied to the electrical joint is determined by using the following values:
a. the design load of the electrical joint; b. the temperature differential; c. the maximum temperature differential allowed; and d. the actual load of the electrical joint.
Preferably the maximum electrical load that can be applied to the electrical joint is determined by:
a. determining the percentage load applied to the electrical joint from the actual load of the electrical joint and the design load of the electrical joint; b. determining what the temperature differential would be at the design load of the electrical joint from the temperature differential and the percentage load applied to the electrical joint determined in step a; c. determining the equivalent temperature load ratio for the maximum temperature differential allowed from the temperature differential determined in step b and the maximum temperature differential allowed; and d. determining the maximum electrical load that can be applied to the electrical joint using the design load of the electrical joint and the equivalent temperature load ratio determined in step c.
This is advantageous as the system provides for the first time a real time continuous detection of compromised joint fails by indicating that a reduced maximum electrical load can be applied to the electrical circuit compared to that which the electrical circuit is designed to handle. The system also calculates the maximum electrical load that can be applied to the electrical circuit before the joint fails so that once a compromised joint has been detected it does not then go on to fail by increasing the electrical load beyond that which it can safely handle. This means that reduced downtime periods would be experienced without catastrophic electrical failures.
Preferably the maximum electrical load that can be applied to the electrical joint is determined by the following calculations:
a
.
(
actual
load
of
electrical
joint
design
load
of
electrical
joint
)
×
100
=
%
load
(
applied
to
the
electrical
joint
)
b
.
100
2
%
load
2
=
temperature
ratio
c
.
temperature
ratio
×
actual
Δ
T
value
=
Δ
T
value
at
design
load
of
electrical
joint
d
.
Δ
T
value
at
design
load
of
electrical
joint
maximum
Δ
T
value
allowed
=
equivalent
temperature
load
ratio
e
.
design
load
of
electrical
joint
equivalent
temperature
load
ratio
=
maximum
electrical
load
Preferably the load calculation device is further adapted to determine if the electrical joint is compromised by comparing the maximum electrical load with the design load of the electrical joint, wherein an electrical joint is compromised if the maximum electrical load is less than the design load of the electrical joint
Alternatively the section of the electrical circuit comprises an electrical conductor remote from an electrical joint.
Preferably the load calculation device further comprises means for determining the maximum conductor temperature allowed for the circuit
According to a third aspect of the present invention the maximum electrical load that can be applied to the electrical circuit when the electrical circuit is at a particular ambient temperature is determined by using the following values:
a. the design load of the electrical circuit; b. the temperature differential; c. the actual load of the electrical joint; d. the maximum conductor temperature allowed for the circuit; and e. the ambient temperature.
This is also advantageous as the system provides for the first time a real time continuous detection of the maximum electrical load that can be passed through an electrical circuit which is at an elevated ambient temperature, i.e. in very hot countries for example. This means that at no time a greater electrical load than that which the electrical circuit can safely handle is applied to the electrical circuit, no matter what the ambient temperature actually is.
Preferably the maximum electrical load that can be applied to the electrical circuit when the electrical circuit is at a particular ambient temperature is determined by:
a. determining the percentage load applied to the electrical circuit from the actual load of the electrical circuit and the design load of the electrical circuit; b. determining what the conductor temperature would be at the design load of the electrical circuit from the temperature differential, the ambient temperature and the percentage load applied to the electrical joint determined in step a; c. determining the equivalent temperature load ratio for the maximum conductor temperature allowed for the circuit from the conductor temperature determined in step b and the maximum conductor temperature allowed for the circuit; d. determining the maximum electrical load that can be applied to the electrical circuit when the electrical circuit is at a particular ambient temperature using the design load of the electrical circuit and the equivalent temperature load ratio.
Preferably the maximum electrical load that can be applied to the electrical circuit when the electrical circuit is at a particular ambient temperature is determined by the following calculations:
a
.
(
electrical
load
of
electrical
circuit
design
load
of
electrical
circuit
)
×
100
=
%
load
(
applied
to
electrical
circuit
)
b
.
100
2
%
load
2
=
temperature
ratio
c
.
temperature
ratio
×
actual
Δ
T
value
=
Δ
T
value
at
100
%
load
d
.
Δ
T
value
at
100
%
load
+
ambient
temperature
=
conductor
temperature
at
design
load
e
.
conductor
temperature
at
design
load
maximum
conductor
temperature
allowed
for
the
circuit
=
equivalent
temperature
load
ratio
f
.
design
load
of
electrical
circuit
equivalent
temperature
load
ratio
=
maximum
load
Preferably the load calculation device is adapted to communicate with a temperature control means adapted to control the air ambient temperature in which the circuit resides.
Preferably the temperature control means is adapted to control the ambient temperature such that the maximum load equals the design load of the electrical circuit.
Preferably the temperature control means is adapted to control the ambient temperature such that the maximum load can be safely increased beyond the design load of the electrical circuit.
Preferably the temperature control means comprises a fan.
Preferably the temperature control means comprises an air conditioning system.
Preferably the temperature control means comprises a liquid cooling system.
Preferably the load calculation device is adapted to calculate the electrical load remaining that can be applied to the electrical joint without exceeding the maximum electrical load.
Preferably the load calculation device is further adapted to prevent the electrical load that can be applied to the electrical joint from exceeding the maximum electrical load.
Preferably the load calculation device is adapted to communicate with a switching means which is adapted to communicate with a control device adapted to supply electrical load to the electrical circuit, such that when the switching means prevents the control device from supplying an electrical load to the electrical circuit that would exceed the maximum electrical load.
This is advantageous as the provision of a load calculation device which prevents more electrical load from being applied to a compromised electrical joint, or an electrical joint at elevated ambient temperature ensures that the electrical joint does not fail by adding more electrical load to the electrical joint than that which it can safely handle.
According to a fourth aspect of the present invention there is provided a load calculation device for monitoring an electrical joint comprising:
a. means for determining the temperature differential (ΔT) between the electrical joint and the ambient air temperature in which the electrical joint resides; b. means for determining the actual electrical load applied to the electrical joint; c. means for determining the design load of the electrical joint; d. means for determining the maximum allowed temperature differential; and e. means for calculating a temperature differential threshold for the electrical load being applied to the electrical joint based on the temperature differential and the electrical load applied to the electrical joint.
Preferably the values are continuously determined by the device in real time.
Preferably the device is further adapted to continuously calculate the temperature differential threshold for the electrical load being applied to the electrical joint in real time.
Preferably the temperature differential threshold for the electrical load being applied to the electrical joint is determined using the following values;
a. the maximum allowed temperature differential; b. the design load of the electrical joint; and c. the actual load of the electrical joint.
Preferably the temperature differential threshold for the electrical load being applied to the electrical joint is determined by:
a. determining the percentage load applied to the electrical joint from the actual load of the electrical joint and the design load of the electrical joint; b. determining the temperature differential threshold for the electrical load of the electrical joint using the design load of the electrical joint and the maximum allowed temperature differential.
Preferably the temperature differential threshold for the electrical load being applied to the electrical joint is determined by the following calculations:
a
.
(
actual
load
of
electrical
joint
design
load
of
electrical
joint
)
×
100
=
%
load
(
applied
to
the
electrical
joint
)
b
.
Maximum
allowed
Δ
T
value
×
(
%
load
100
)
2
=
Δ
T
value
threshold
Preferably the load calculation device determines whether the electrical joint is compromised by comparing the temperature differential threshold with the actual temperature differential.
Preferably the electrical joint is determined to be compromised when the actual temperature differential is greater than the temperature differential threshold.
Preferably the load calculation device further comprising an alarm and wherein the alarm is activated when the actual temperature differential is greater than the temperature differential threshold to notify that a compromised electrical joint has been located.
According to a fifth aspect of the present invention there is provided a load calculation device comprising a load calculation device for determining the maximum electrical load that can be applied to an electrical circuit and a load calculation device for monitoring an electrical joint.
According to a sixth aspect of the present invention there is provided a system comprising:
a. a load calculation device as described in relation to any of the first to firth aspects of the present invention; b. a first sensing element for determining the temperature of the section of the electrical circuit; and c. a second sensing means for determining the ambient air temperature in which the section of the electrical circuit resides.
According to a seventh aspect of the present invention there is provided a method for determining the maximum electrical load that can be applied to an electrical circuit comprising:
a. determining the temperature differential (ΔT) between a section of the electrical circuit and the ambient air temperature in which the section of the electrical circuit resides; b. determining the actual electrical load applied to the electrical circuit; c. determining the design load of the electrical circuit; d. determining the maximum electrical load that can be applied to the electrical circuit based on the temperature differential and the electrical load applied to the electrical circuit.
Preferably the maximum electrical load that can be applied to the electrical circuit is continuously determined in real time. This means that the values are determined every 0.5 to 30 seconds.
Preferably the values are continuously determined in real time. This means that the values are determined or calculated every 0.5 to 30 seconds.
Preferably the temperature differential is determined by determining the temperature of the section of the electrical circuit and determining the temperature of the ambient air in which the electrical circuit resides.
The sensing elements may be for example:
A combined sensing element located close to the electrical joint which has a first sensing element which measures the temperature of the electrical joint or the temperature of the electrical conductor adjacent the electrical joint using non contact infrared for example, or a contact device such as a thermocouple or a fibre optic sensing device, and a second sensing element which measures the ambient air temperature within the enclosure. In one alternative such a combined sensing element sends each measurement separately to the local calculation device. In an alternative such a combined sensing element is provided with a device adapted to determine the ΔT value of the electrical joint or of the conductor adjacent the electrical joint which is effectively the ΔT value of the joint and the combined sensing element sends the ΔT value to the local calculation device. Separate contact or non contact sensing elements, the first sensing element located above the electrical joint which measures the temperature of the electrical joint or the temperature of the electrical conductor adjacent the electrical joint using infrared for example, and the second sensing element located remote from the first sensing element but still within the enclosure which measures the ambient air temperature within the enclosure. The load calculation device would then determine the ΔT value based on the individual temperature values. Separate linked elements, the first sensing element is located near or on the external insulating layer of an electrical conductor, in the case of an electrical cable, adjacent to the electrical joint which measures the temperature of the electrical conductor adjacent to the electrical joint which is connected to the second sensing element located remote from the first sensing element but still within the enclosure which measures the ambient air temperature within the enclosure wherein the second sensing element is provided with a device adapted to determine the ΔT value of the electrical conductor adjacent to the electrical joint which is effectively the ΔT value of the electrical joint which then sends the ΔT value to the load calculation device.
Preferably the section of the electrical circuit comprises an electrical joint.
Preferably the method further comprises determining the maximum temperature differential allowed.
According to an eighth aspect of the present invention the maximum electrical load that can be applied to the electrical joint is determined by using the following values:
a. the design load of the electrical joint; b. the temperature differential; c. the maximum temperature differential allowed; and d. the actual load of the electrical joint.
Preferably the maximum electrical load that can be applied to the electrical joint is determined by:
a. determining the percentage load applied to the electrical joint from the actual load of the electrical joint and the design load of the electrical joint; b. determining what the temperature differential would be at the design load of the electrical joint from the temperature differential and the percentage load applied to the electrical joint determined in step a; c. determining the equivalent temperature load ratio for the maximum temperature differential allowed from the temperature differential determined in step b and the maximum temperature differential allowed; and d. determining the maximum electrical load that can be applied to the electrical joint using the design load of the electrical joint and the equivalent temperature load ratio determined in step c.
This is advantageous as the method provides for the first time a real time continuous detection of compromised electrical joints in electrical circuits, before the compromised joint fails by determining that a reduced maximum electrical load can be applied to the electrical joint compared to that which the electrical joint is designed to handle. The method also calculates the maximum electrical load that can be applied to the electrical joint before it fails so that once a compromised joint has been detected it does not then go on to fail by increasing the electrical load beyond that which it can safely handle. This means that reduced downtime periods would be experienced without catastrophic electrical failures.
Preferably the maximum electrical load that can be applied to the electrical joint is determined by the following calculations:
a
.
(
actual
load
of
electrical
joint
design
load
of
electrical
joint
)
×
100
=
%
load
(
applied
to
the
electrical
joint
)
b
.
100
2
%
load
2
=
temperature
ratio
c
.
temperature
ratio
×
actual
Δ
T
value
=
Δ
T
value
at
design
load
of
electrical
joint
d
.
Δ
T
value
at
design
load
of
electrical
joint
maximum
Δ
T
value
allowed
=
equivalent
temperature
load
ratio
e
.
design
load
of
electrical
joint
equivalent
temperature
load
ratio
=
maximum
electrical
load
Preferably the method further comprises determining if the electrical joint is compromised by comparing the maximum electrical load with the design load of the electrical joint, wherein an electrical joint is compromised if the maximum electrical load is less than the design load of the electrical joint.
Preferably the section of the electrical circuit comprises an electrical conductor remote from an electrical joint.
Preferably the method further comprises determining the maximum conductor temperature allowed for the circuit.
According to a ninth aspect of the present invention the maximum electrical load that can be applied to the electrical circuit when the electrical circuit is at a particular ambient temperature is determined by using the following values:
a. the design load of the electrical circuit; b. the temperature differential; c. the actual load of the electrical joint; d. the maximum conductor temperature allowed for the circuit; and e. the ambient temperature.
This is also advantageous as the method provides for the first time a real time continuous detection of the maximum electrical load that can be passed through an electrical joint which is at an elevated ambient temperature, i.e. in very hot countries for example. This means that at no time a greater electrical load than that which the electrical joint can safely handle is applied to the electrical joint, no matter what the ambient temperature.
Preferably the maximum electrical load that can be applied to the electrical circuit when the electrical circuit is at a particular ambient temperature is determined by:
a. determining the percentage load applied to the electrical circuit from the actual load of the electrical circuit and the design load of the electrical circuit; b. determining what the conductor temperature would be at the design load of the electrical circuit from the temperature differential, the ambient temperature and the percentage load applied to the electrical joint determined in step a; c. determining the equivalent temperature load ratio for the maximum conductor temperature allowed for the circuit from the conductor temperature determined in step b and the maximum conductor temperature allowed for the circuit; d. determining the maximum electrical load that can be applied to the electrical circuit when the electrical circuit is at a particular ambient temperature using the design load of the electrical circuit and the equivalent temperature load ratio.
Preferably the maximum electrical load that can be applied to the electrical circuit when the electrical circuit is at a particular ambient temperature is determined by the following calculations:
a
.
(
electrical
load
of
electrical
circuit
design
load
of
electrical
circuit
)
×
100
=
%
load
(
applied
to
electrical
circuit
)
b
.
100
2
%
load
2
=
temperature
ratio
c
.
temperature
ratio
×
actual
Δ
T
value
=
Δ
T
value
at
100
%
load
d
.
Δ
T
value
at
100
%
load
+
ambient
temperature
=
conductor
temperature
at
design
load
e
.
conductor
temperature
at
design
load
maximum
conductor
temperature
allowed
for
the
circuit
=
equivalent
temperature
load
ratio
f
.
design
load
of
electrical
circuit
equivalent
temperature
load
ratio
=
maximum
load
Preferably the method further comprises communicating with a temperature control means adapted to control the air ambient temperature in which the section of the circuit resides.
Preferably the temperature control means is adapted to control the ambient temperature such that the maximum load equals the design load of the electrical circuit.
Preferably the temperature control means is adapted to control the ambient temperature such that the maximum load can be safely increased beyond the design load of the electrical circuit.
Preferably the temperature control means comprises a fan.
Preferably the temperature control means comprises an air conditioning system.
Preferably the temperature control means comprises a liquid cooling system.
Preferably the method further comprises calculating the electrical load remaining that can be applied to the electrical joint without exceeding the maximum electrical load.
Preferably the method further comprises preventing the electrical load that can be applied to the electrical joint from exceeding the maximum electrical load.
Preferably the method further comprises communicating with a switching means which is adapted to communicate with a control device adapted to supply electrical load to the electrical circuit, such that when the switching means prevents the control device from supplying an electrical load to the electrical circuit that would exceed the maximum electrical load.
This is advantageous as the provision of a method which prevents more electrical load from being applied to a compromised electrical joint, or an electrical joint at elevated ambient temperature ensures that the electrical joint does not fail by adding more electrical load to the electrical joint than that which it can safely handle.
According to a tenth aspect of the present invention there is provided a method for determining the temperature differential threshold for an electrical load being applied to an electrical joint comprising:
a. determining the temperature differential (ΔT) between the electrical joint and the ambient air temperature in which the electrical joint resides; b. determining the actual electrical load applied to the electrical joint; c. determining the design load of the electrical joint; d. determining the maximum allowed temperature differential; and e. determining the temperature differential threshold for the electrical load being applied to the electrical joint based on the temperature differential and the electrical load applied to the electrical joint.
Preferably the values are continuously determined in real time.
Preferably the temperature differential threshold for the electrical load being applied to the electrical joint is continuously determined in real time.
Preferably the temperature differential threshold for the electrical load being applied to the electrical joint is determined using the following values;
a. the maximum allowed temperature differential; b. the design load of the electrical joint; and c. the actual load of the electrical joint.
Preferably the temperature differential threshold for the electrical load being applied to the electrical joint is determined by:
a. determining the percentage load applied to the electrical joint from the actual load of the electrical joint and the design load of the electrical joint; b. determining the temperature differential threshold for the electrical load of the electrical joint using the design load of the electrical joint and the maximum allowed temperature differential.
Preferably the temperature differential threshold for the electrical load being applied to the electrical joint is determined by the following calculations:
a
.
(
actual
load
of
electrical
joint
design
load
of
electrical
joint
)
×
100
=
%
load
(
applied
to
the
electrical
joint
)
b
.
Maximum
allowed
ΔT
value
×
(
%
load
100
)
2
=
ΔT
value
threshold
Preferably the method further comprises determining whether the electrical joint is compromised by comparing the temperature differential threshold with the actual temperature differential.
Preferably the electrical joint is determined to be compromised when the actual temperature differential is greater than the temperature differential threshold.
Preferably the method further comprises activating an alarm when the actual temperature differential is greater than the temperature differential threshold to notify that a compromised electrical joint has been located.
According to an eleventh aspect of the present invention there is provided a method comprising a method for determining the maximum electrical load that can be applied to an electrical circuit and a method for determining the temperature differential threshold for an electrical load being applied to an electrical joint.
According to a twelfth aspect of the present invention there is provided a computer program embedded in a computer readable media that when executed by a device causes the device to perform the method according to any of the seventh to eleventh aspects of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of example only, with reference to the accompanying drawing in which:
FIG. 1 illustrates an exemplary electrical circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention are described below by way of example only. These embodiments represent the best ways of putting the invention into practice that are currently known to the Applicant, although they are not the only ways in which this could be achieved.
FIG. 1 shows an exemplary electrical circuit 10 illustrating two types of electrical joints 12 , 14 between different types of conductor 14 , 16 . 18 . The electrical joint 14 may be for example a joint between metal connectors 16 , 18 , which are typically formed from copper or aluminium, or the joint 12 may be at the termination of an electric cable 20 to a metal connector 16 , or any other joint in an electrical circuit between two or more components.
The electrical joint 12 , 14 is provided with a first sensing element 22 , 24 which measures the temperature of the electrical joint 12 , 14 . The first sensing element 22 , 24 is located within the electrical enclosure in which the electrical circuit 10 is located so that the temperature of the electrical joint is obtained accurately and without any need for correlation. The first sensing element 22 is an example of a non contact temperature sensor. The first sensing element 22 may either measure the temperature of the electrical joint 14 or the temperature of the electrical conductor 16 adjacent the electrical joint 14 as this will be at around the same temperature. The first sensing element 24 is an example of a cable mounted contact temperature sensor. The first sensing element 24 may measures the temperature of the electrical cable 24 adjacent the electrical joint 12 as this will be at around the same temperature as that of the electrical joint 12 itself.
A second sensing element 26 , 28 is also provided within the electrical enclosure in which the electrical circuit 10 is located which measures the ambient temperature of the air within the electrical enclosure. The second sensing element 26 is an example where the local ambient temperature sensor is remote from the first sensing element and not directly connected thereto. The second sensing element 28 is an example of where the local ambient temperature sensor is connected to the first sensing element 24 .
The second sensing element may be separate from the first sensing element or combined with the first sensing element.
The temperature differential or ΔT value of the electrical joint is the difference between the temperature of the electrical joint (or the electrical conductor adjacent thereto) and the ambient temperature.
The sensing elements may be for example:
A combined sensing element located close to the electrical joint which has a first sensing element which measures the temperature of the electrical joint or the temperature of the electrical conductor adjacent the electrical joint using non contact infrared for example, or a contact device such as a thermocouple or a fibre optic sensing device, and a second sensing element which measures the ambient air temperature within the enclosure. In one alternative such a combined sensing element sends each measurement separately to the local calculation device. In an alternative such a combined sensing element is provided with a device adapted to determine the ΔT value of the electrical joint or of the conductor adjacent the electrical joint which is effectively the ΔT value of the joint and the combined sensing element sends the ΔT value to the local calculation device. Separate contact or non contact sensing elements, the first sensing element located above the electrical joint which measures the temperature of the electrical joint or the temperature of the electrical conductor adjacent the electrical joint using infrared for example, and the second sensing element located remote from the first sensing element but still within the enclosure which measures the ambient air temperature within the enclosure. The load calculation device would then determine the ΔT value based on the individual temperature values. Separate linked elements, the first sensing element is located near or on the external insulating layer of an electrical conductor, in the case of an electrical cable, adjacent to the electrical joint which measures the temperature of the electrical conductor adjacent to the electrical joint which is connected to the second sensing element located remote from the first sensing element but still within the enclosure which measures the ambient air temperature within the enclosure wherein the second sensing element is provided with a device adapted to determine the ΔT value of the electrical conductor adjacent to the electrical joint which is effectively the ΔT value of the electrical joint which then sends the ΔT value to the load calculation device.
In the instances where the local calculation device is provided with the ΔT value directly it may be necessary to provide a secondary ambient temperature sensing element where it is necessary to know the ambient temperature separately from the ΔT value. In these instances though it is only necessary to provide one such additional sensing element per enclosure.
Furthermore, when it is known that none of the electrical joints are compromised and one desires to run an electrical circuit either at elevated electrical loads or elevated ambient temperatures, as discussed in detail later, it is only necessary to provide a single first sensing element which either measures the temperature of the conductor or joint and a second sensing element which measures the ambient air temperature per enclosure.
The first and second sensing elements 22 , 24 , 26 , 28 are either directly or indirectly connected to a load calculation device 30 which continuously receives and may additionally log the temperature values which have been continuously measured by each of the first and second sensing elements 22 , 24 , 26 , 28 , to provide the load calculation device 30 with real time data. The load calculation device 30 may receive the temperature values via a cable or via wireless means.
The electrical circuit is also provided with a metering device 32 , 34 , 36 , 38 which continuously monitors the electrical load being put through the electrical circuit (i.e. the electrical current). In FIG. 1 the metering devices 32 , 34 , 36 are integrated energy meters located within the electrical circuit and metering device 38 is a third party energy meter located externally to the electrical circuit.
The metering device 32 , 34 , 36 , 38 may be directly connected to the load calculation device 30 or in the alternative the metering device 32 , 34 , 36 , 38 may be indirectly connected to the load calculation device 30 via a secondary system to which the metering device 32 , 34 , 36 , 38 is connected to such as a building management system, electrical monitoring system, power management system or the like.
The load calculation device 30 continuously receives and may additionally log the electrical load values which have been continuously provided by the metering device 32 , 34 , 36 , 38 , to provide the software with real time data. The load calculation device 30 may receive the electrical load values via cable or via wireless means.
The load calculation device 30 may be located remote from the electrical circuit 10 and thus the electrical joint 12 , 14 .
The load calculation device 30 may be for example a computer provided with computer software, in the alternative the load calculation device may be PLCs (process logic controllers), process control devices, automation control devices, processors for process control devices or the like.
Method of Determining the Electrical Load that can be Applied to a Compromised Electrical Joint
The load calculation device, using the maximum electrical load the electrical circuit and thus the electrical joint is designed to operate at, the ΔT value of the electrical joint and actual electrical load, continuously calculates the maximum electrical load that the electrical joint can safely handle in real time. The load calculation device also continuously calculates the remaining electrical load that the electrical joint can safely handle and the ΔT value that the electrical joint will reach if operated at the maximum electrical load that the electrical circuit and thus the electrical joint is designed to operate at.
The load calculation device uses the following calculations to continuously calculate in real time the maximum safe operating electrical load for the electrical joint and the remaining electrical load that can be placed on the electrical joint before the maximum electrical load that the electrical joint can safely operate at is exceeded. It should be noted that the electrical load that the electrical circuit is designed to operate at is the same as the electrical load that the electrical joint is designed to operate at.
(
actual
load
of
electrical
joint
design
load
of
electrical
joint
)
×
100
=
%
load
(
applied
to
the
electrical
joint
)
100
2
%
load
2
=
temperature
ratio
temperature
ratio
×
actual
Δ
T
value
=
ΔT
value
at
design
load
of
electrical
joint
ΔT
value
at
design
load
of
electrical
joint
maximum
ΔT
value
allowed
=
equivalent
temperature
load
ratio
design
load
of
electrical
joint
equivalent
temperature
load
ratio
=
maximum
electrical
load
maximum
load
-
actual
load
of
electrical
joint
=
load
remaining
Equation
Set
1
The load remaining value is provided with a cap to stop this value from exceeding [design load of electrical joint−actual load of electrical joint], should the ambient temperature of the air within the enclosure be below 40° C. at full electrical load values for example.
Example 1
Actual electrical joint load=201 Amps
Design electrical joint load=619 Amps
Actual ΔT=4.5° C.
Maximum ΔT=40° C.
(
201
619
)
×
100
=
32.47
%
100
2
32.47
2
=
10000
1054.30
=
9.48
9.48
×
4.5
°
C
.
=
42.66
°
C
.
42.66
40.00
=
1.03
619
1.03
=
600.97
Amps
maximum
load
600.97
-
201
=
399.97
Amps
remaining
before
the
electrical
joint
and
thus
the
electrical
circuit
exceeds
maximum
allowed
ΔT
value
of
40
°
C
.
The load calculation device would therefore calculate in real time:
maximum electrical load of 600.97 Amps that the electrical joint and thus the electrical circuit can safely handle; remaining load of 399.97 Amps that we can expect the electrical joint and thus the electrical circuit to safely handle; ΔT value of 42.66° C. that the electrical joint will reach if allowed to run at the design load of the electrical circuit, and thus the design load of the electrical joint.
The load calculation device provides to the operator in real time;
current ΔT value that the electrical joint is operating at in ° C. or ° F.; design load of the electrical circuit and thus the design load of the electrical joint in Amps; actual electrical load applied to the electrical joint in Amps; ΔT value of the electrical joint if 100% electrical joint design load is applied to the electrical joint in ° C.; maximum electrical load, that can be applied to the electrical joint so that it still operates safely and below a given actual temperature threshold, in Amps;
along with other interactive capabilities.
The load calculation device continuously monitors the values and makes the calculations to enable the user to locate compromised electrical joints at any operating electrical loads in real time. The load calculation device also calculates in real time the additional electrical load that can be safely handled by the electrical joint and thus the electrical circuit. This means that any such compromised joints do not have additional electrical load applied to them which otherwise result in failure of the compromised joint along with associated safety issues and economic loss. In addition the load calculation device can be used to identify the degeneration of an electrical joint in an electrical circuit over the lifetime of the electrical circuit to enable for accurate determination of when the electrical circuit and/or joint should be replaced or its electrical load capacity reduced.
The load calculation device may additionally be provided with a stop mechanism that prevents the electrical load being applied to the electrical joint from being increased beyond the safe maximum electrical load in the event that a compromised electrical joint has been located by the load calculation device, i.e. when safe maximum electrical load is less than the design load of the electrical joint and thus the electrical circuit.
Method of Determining the Electrical Load that can be Applied to an Electrical Circuit at a Given Ambient Temperature
The load calculation device, using the maximum electrical load the circuit is designed to operate at, the ΔT value of the electrical conductor, which may be the ΔT value of an electrical joint or the ΔT value of the conductor remote from an electrical joint, actual circuit load and ambient temperature, continuously calculates in real time the maximum electrical load that the electrical circuit can safely handle. The load calculation device also continuously calculates in real time the remaining electrical load that the electrical circuit can safely handle and the actual conductor temperature that the conductor will reach if operated at the maximum electrical load that the electrical circuit is designed to operate at and thus the amount that the ambient temperature would need to be reduced by to allow the electrical circuit to be operated at maximum load without exceeding the maximum allowed temperature for the electrical circuit.
In the case where the ΔT value of the electrical conductor is taken at a point remote from an electrical joint the load calculation device will assume that none of the electrical joints in the electrical circuit have been compromised and furthermore will not be able to detect if any of the electrical joints have been compromised. In the case where the ΔT value of the electrical conductor is taken at or adjacent to an electrical joint the load calculation device will, in addition to calculating the correct safe electrical load for a given ambient temperature, be able to detect if such an electrical joint has been compromised and factor this into the calculations to calculate the correct safe electrical load for a given ambient temperature.
The load calculating device uses the following calculations to continuously calculate in real time the maximum safe operating electrical load for the electrical circuit and the remaining electrical load that can be placed on the electrical circuit before the maximum electrical load that the electrical circuit can safely be operated at is exceeded for the ambient temperature. The following calculations assume that the ΔT value is taken on a conductor at a point remote from any electrical joints. However, if it also desired to detect any compromised joints and adjust the electrical load to take into account any such compromised joints as well as the ambient temperature such calculations are combined with those provided in Equation Set 1 that are used to determine the electrical load that can be applied to a compromised electrical joint as set out in Equation Set 3 and Example 3 further below.
(
electrical
load
of
electrical
circuit
design
load
of
electrical
circuit
)
×
100
=
%
load
(
applied
to
electrical
circuit
)
100
2
%
load
2
=
temperature
ratio
temperature
ratio
×
actual
Δ
T
value
=
ΔT
value
at
100
%
load
ΔT
value
at
100
%
load
+
ambient
temperature
=
conductor
temperature
at
design
load
conductor
temperature
at
design
load
maximum
conductor
temperature
allowed
for
the
circuit
=
equivalent
temperature
load
ratio
design
load
of
electrical
circuit
equivalent
temperature
load
ratio
=
maximum
load
maximum
load
-
actual
load
of
electrical
circuit
=
load
remaining
The load remaining value is provided with a cap to stop this value from exceeding [design load of electrical circuit−actual load of electrical circuit], should the conductor temperature be below 85° C. at full load values for example, or other standard as required.
Using the above equations the load calculation device continuously calculates in real time the value of the maximum electrical load a given electrical circuit can safely operate at before exceeding the given threshold for temperature rise on the conductors in the electrical circuit which is for example 85° C. as set out in BS159, and the value of the remaining electrical load that can be placed on the circuit before the maximum electrical load for the given circuit is exceeded. ANSI, IEC and UL have similar standards and the actual threshold for temperature rise will depend on the particular standard that is in force and recommended by each manufacturer.
Example 2
Actual circuit load=201 Amps
Design circuit load=619 Amps
Actual ΔT=6.0° C.
Ambient temperature=35° C.
(
201
619
)
×
100
=
32.47
%
100
2
32.47
2
=
10000
1054.30
=
9.48
9.48
×
6.0
°
C
.
=
56.88
°
C
.
56.88
°
C
.
+
35.00
°
C
.
=
91.88
°
C
.
(
actual
joint
temperature
)
91.88
85.00
=
1.04
619
1.04
=
595.19
Amps
maximum
electrical
load
595.19
-
201
=
394.19
Amps
remaining
before
circuit
exceeds
maximum
allowed
conductor
temperature
of
85
°
C
.
The load calculation device would therefore calculate in real time:
maximum electrical load of 595.19 Amps that the circuit can safely handle; remaining load of 394.19 Amps that we can expect the circuit to safely handle; an actual temperature of the electrical joint of 91.88° C. that the electrical joint will reach if allowed to run at the design circuit load.
The load calculation device then subtracts the maximum allowed electrical conductor temperature from the actual conductor temperature, i.e. 85.0° C.-91.88° C., to provide the value that the ambient temperature needs to be reduced by to bring the conductor temperature in line with the acceptable standards i.e. 6.88° C.
The load calculation device provides to the operator continuously in real time;
current ΔT that the electrical conductor is operating at in ° C. or ° F.; design load of the electrical circuit and thus the electrical conductor in Amps; actual electrical load applied to the electrical circuit and thus the electrical conductor in Amps; local ambient temperature in ° C. or ° F.; the temperature that the electrical conductor will reach if 100% electrical load is applied to the electrical conductor in ° C. or ° F.; the maximum electrical load that can be applied to the electrical conductor and thus the electrical circuit to stay below the defined threshold in Amps; the remaining electrical load that can be safely applied to the electrical circuit in Amps; the reduction in ambient temperature required to bring the electrical conductor in line with the applicable standard, or other threshold in ° C. or ° F.;
along with other interactive capabilities.
The temperature reduction can be achieved manually or may be automatically provided by the load calculation device which may for example automatically start cooling fans or liquid cooling systems such as water cooling devices located close to the electrical circuit within the enclosure for example or lower the temperature of the room or other enclosure in which the electrical circuit is located. In addition the load calculation device may communicate with a BMS/SCADA system to facilitate such changes in room or enclosure temperature.
This means that the operator would know in real time the maximum electrical load that could be applied to an electrical circuit based on the real time ambient temperature. This also means that the ambient temperature could be cooled by the required amounts to safely allow the electrical circuit to operate at 100% electrical load in elevated ambient temperatures. Similarly the load calculation device allows for safe operation of the electrical circuit at levels above 100% electrical load by reducing the ambient temperature to compensate. In addition the load calculation device can be used to identify the degeneration of an electrical joint in an electrical circuit over the lifetime of the electrical circuit to enable for accurate determination of when the electrical circuit and/or joint should be replaced or its electrical load capacity reduced.
In the case where it is also desired to detect any compromised electrical joints and adjust the electrical load to take into account any such compromised electrical joints as well as the ambient temperature the load calculation devices uses both of the calculations detailed above wherein the ΔT values are taken at or adjacent to such electrical joints. Once the load calculation device has made the two sets of calculations, the lowest maximum electrical load calculated is taken to be the maximum electrical load for the electrical joint taking into account both the ambient temperature and integrity of the electrical joint.
Method of Determining the ΔT Value Threshold an Electrical Joint at any Electrical Load
The load calculation device also provides for a dynamic ΔT value threshold. This allows for an alarm or other signal to be set off when a compromised electrical joint is identified irrespective of the electrical load being applied to the electrical joint.
The load calculation device uses the maximum allowed ΔT value of the electrical joint and the % electrical load to calculate the ΔT value alarm threshold using the following calculations.
Equation Set 3
(
actual
load
of
electrical
joint
design
load
of
electrical
joint
)
×
100
=
%
load
(
applied
to
the
electrical
joint
)
Maximum
allowed
ΔT
value
×
(
%
load
100
)
2
=
ΔT
value
threshold
Example 3
For a maximum allowed ΔT value of 40° the ΔT value threshold at 40% electrical load is calculated as follows:
40
×
(
40
100
)
2
=
6.4
°
C
.
ΔT
value
threshold
The load calculation device provides to the operator continuously in real time;
current ΔT value that the electrical joint is operating at in ° C. or ° F.; design load of the electrical circuit and thus the electrical joint in Amps; actual electrical load applied to the electrical circuit and thus the electrical joint in Amps; ΔT value alarm threshold for the % electrical load utilized on the circuit in ° C. or ° F., equivalent to that which would apply at 100% electrical load.
along with other interactive capabilities. | A load calculation device for determining the maximum electrical load that can be applied to an electrical circuit includes determines the temperature differential (ΔT) between a section of the electrical circuit and the ambient air temperature in which the section of the electrical circuit resides. The actual electrical load applied to the electrical circuit is also determined as is the design load of the electrical circuit. The maximum electrical load that can be applied to the electrical circuit is then determined based on the temperature differential and the electrical load applied to the electrical circuit and the circuit designed load. The load calculation device may be applied to an electrical joint and may be used to calculate the maximum temperature differential allowed for a given current to be applied at the electrical joint. This is particularly beneficial in connection with detecting and preventing electrical joint failure. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation and claims the benefit of priority under 35 USC §120 to U.S. application Ser. No. 14/302,662, filed Jun. 12, 2014, which is a continuation of U.S. application Ser. No. 12/639,963, filed Dec. 16, 2009, now U.S. Pat. No. 8,760,007, which is a continuation of U.S. application Ser. No. 12/553,957, filed Sep. 3, 2009, which is a continuation of U.S. application Ser. No. 11/481,077 filed Jul. 5, 2006, now U.S. Pat. No. 7,741,734, which claims priority under 35 USC §119(e) to U.S. provisional application Ser. No. 60/698,442 filed Jul. 12, 2005. The contents of the prior applications mentioned above are incorporated herein by reference in their entirety.
STATEMENT AS TO FEDERALLY FUNDED RESEARCH
[0002] This invention was made with government support awarded by the National Science Foundation under Grant No. DMR-0213282. The government has certain rights in this invention.
BACKGROUND OF THE INVENTION
[0003] The invention relates to the field of oscillatory resonant electromagnetic modes, and in particular to oscillatory resonant electromagnetic modes, with localized slowly evanescent field patterns, for wireless non-radiative energy transfer.
[0004] In the early days of electromagnetism, before the electrical-wire grid was deployed, serious interest and effort was devoted towards the development of schemes to transport energy over long distances wirelessly, without any carrier medium. These efforts appear to have met with little, if any, success. Radiative modes of omni-directional antennas, which work very well for information transfer, are not suitable for such energy transfer, because a vast majority of energy is wasted into free space. Directed radiation modes, using lasers or highly-directional antennas, can be efficiently used for energy transfer, even for long distances (transfer distance L TRANS>> L DEV , where L DEV is the characteristic size of the device), but require existence of an uninterruptible line-of-sight and a complicated tracking system in the case of mobile objects.
[0005] Rapid development of autonomous electronics of recent years (e.g. laptops, cell-phones, house-hold robots, that all typically rely on chemical energy storage) justifies revisiting investigation of this issue. Today, the existing electrical-wire grid carries energy almost everywhere; even a medium-range wireless non-radiative energy transfer would be quite useful. One scheme currently used for some important applications relies on induction, but it is restricted to very close-range (L TRANS<< L DEV ) energy transfers.
SUMMARY OF THE INVENTION
[0006] According to one aspect of the invention, there is provided an electromagnetic energy transfer device. The electromagnetic energy transfer device includes a first resonator structure receiving energy from an external power supply. The first resonator structure has a first Q-factor. A second resonator structure is positioned distal from the first resonator structure, and supplies useful working power to an external load. The second resonator structure has a second Q-factor. The distance between the two resonators can be larger than the characteristic size of each resonator. Non-radiative energy transfer between the first resonator structure and the second resonator structure is mediated through coupling of their resonant-field evanescent tails.
[0007] According to another aspect of the invention, there is provided a method of transferring electromagnetic energy. The method includes providing a first resonator structure receiving energy from an external power supply. The first resonator structure has a first Q-factor. Also, the method includes a second resonator structure being positioned distal from the first resonator structure, and supplying useful working power to an external load. The second resonator structure has a second Q-factor. The distance between the two resonators can be larger than the characteristic size of each resonator. Furthermore, the method includes transferring non-radiative energy between the first resonator structure and the second resonator structure through coupling of their resonant-field evanescent tails.
[0008] In another aspect, a method of transferring energy is disclosed including the steps of providing a first resonator structure receiving energy from an external power supply, said first resonator structure having a first resonant frequency ω 1 , and a first Q-factor Q 1 , and characteristic size L 1 . Providing a second resonator structure being positioned distal from said first resonator structure, at closest distance D, said second resonator structure having a second resonant frequency ω 2 , and a second Q-factor Q 2 , and characteristic size L 2 , where the two said frequencies ω 1 and ω 2 are close to within the narrower of the two resonance widths Γ 1 , and Γ 2 , and transferring energy non-radiatively between said first resonator structure and said second resonator structure, said energy transfer being mediated through coupling of their resonant-field evanescent tails, and the rate of energy transfer between said first resonator and said second resonator being denoted by κ, where non-radiative means D is smaller than each of the resonant wavelengths λ 1 and λ 2 , where c is the propagation speed of radiation in the surrounding medium.
[0009] Embodiments of the method may include any of the following features. In some embodiments, said resonators have Q 1 >100 and Q 2 >100, Q 1 >200 and Q 2 >200, Q 1 >500 and Q 2 >500, or even Q 1 >1000 and Q 2 >1000. In some such embodiments, κ/sqrt(Γ 1 *Γ 2 ) may be greater than 0.2, greater than 0.5, greater than 1, greater than 2, or even grater than 5. In some such embodiments D/L 2 may be greater than 1, greater than 2, greater than 3, greater than 5.
[0010] In another aspect, an energy transfer device is disclosed which includes: a first resonator structure receiving energy from an external power supply, said first resonator structure having a first resonant frequency ω 1 , and a first Q-factor Q 1 , and characteristic size L 1 , and a second resonator structure being positioned distal from said first resonator structure, at closest distance D, said second resonator structure having a second resonant frequency ω 2 , and a second Q-factor Q 2 , and characteristic size L 2 .
[0011] The two said frequencies ω 1 and ω 2 are close to within the narrower of the two resonance widths Γ 1 , and Γ 2 . The non-radiative energy transfer between said first resonator structure and said second resonator structure is mediated through coupling of their resonant-field evanescent tails, and the rate of energy transfer between said first resonator and said second resonator is denoted by κ. The non-radiative means D is smaller than each of the resonant wavelengths λ 1 , and λ 2 , where c is the propagation speed of radiation in the surrounding medium.
[0012] Embodiments of the device may include any of the following features. In some embodiments, said resonators have Q 1 >100 and Q 2 >100, Q 1 >200 and Q 2 >200, Q 1 >500 and Q 2 >500, or even Q 1 >1000 and Q 2 >1000. In some such embodiments, κ/sqrt(Γ 1 *Γ 2 ) may be greater than 0.2, greater than 0.5, greater than 1, greater than 2, or even grater than 5. In some such embodiments D/L 2 may be greater than 1, greater than 2, greater than 3, or even greater than 5.
[0013] In some embodiments, the resonant field in the device is electromagnetic.
[0014] In some embodiments, the first resonator structure includes a dielectric sphere, where the characteristic size L 1 is the radius of the sphere.
[0015] In some embodiments, the first resonator structure includes a metallic sphere, where the characteristic size L 1 is the radius of the sphere.
[0016] In some embodiments, the first resonator structure includes a metallodielectric sphere, where the characteristic size L 1 is the radius of the sphere.
[0017] In some embodiments, the first resonator structure includes a plasmonic sphere, where the characteristic size L 1 is the radius of the sphere.
[0018] In some embodiments, the first resonator structure includes a polaritonic sphere, where the characteristic size L 1 is the radius of the sphere.
[0019] In some embodiments, the first resonator structure includes a capacitively-loaded conducting-wire loop, where the characteristic size L 1 is the radius of the loop.
[0020] In some embodiments, the second resonator structure includes a dielectric sphere, where the characteristic size L 2 is the radius of the sphere. In some embodiments, the second resonator structure includes a metallic sphere where the characteristic size L 2 is the radius of the sphere.
[0021] In some embodiments, the second resonator structure includes a metallodielectric sphere where the characteristic size L 2 is the radius of the sphere.
[0022] In some embodiments, the second resonator structure includes a plasmonic sphere where the characteristic size L 2 is the radius of the sphere.
[0023] In some embodiments, the second resonator structure includes a polaritonic sphere where the characteristic size L 2 is the radius of the sphere.
[0024] In some embodiments, the second resonator structure includes a capacitively-loaded conducting-wire loop where the characteristic size L 2 is the radius of the loop.
[0025] In some embodiments, the resonant field in the device is acoustic.
[0026] It is to be understood that embodiments of the above described methods and devices may include any of the above listed features, alone or in combination.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a schematic diagram illustrating an exemplary embodiment of the invention;
[0028] FIG. 2A is a numerical FDTD result for a high-index disk cavity of radius r along with the electric field; FIG. 2B a numerical FDTD result for a medium-distance coupling between two resonant disk cavities: initially, all the energy is in one cavity (left panel); after some time both cavities are equally excited (right panel).
[0029] FIG. 3 is schematic diagram demonstrating two capacitively-loaded conducting-wire loops;
[0030] FIGS. 4A-4B are numerical FDTD results for reduction in radiation-Q of the resonant disk cavity due to scattering from extraneous objects;
[0031] FIG. 5 is a numerical FDTD result for medium-distance coupling between two resonant disk cavities in the presence of extraneous objects; and
[0032] FIGS. 6A-6B are graphs demonstrating efficiencies of converting the supplied power into useful work (η w ) radiation and ohmic loss at the device (η d ), and the source (η s ), and dissipation inside a human (η h ), as a function of the coupling-to-loss ratio κ/Γ d ; in panel (a) Γ w is chosen so as to minimize the energy stored in the device, while in panel (b) Γ w is chosen so as to maximize the efficiency η w for each κ/Γ d .
[0033] FIG. 7 is a schematic diagram of a feedback mechanism to correct the resonators exchanging wireless energy for detuning because of the effect of an extraneous object.
DETAILED DESCRIPTION OF THE INVENTION
[0034] In contrast to the currently existing schemes, the invention provides the feasibility of using long-lived oscillatory resonant electromagnetic modes, with localized slowly evanescent field patterns, for wireless non-radiative energy transfer. The basis of this technique is that two same-frequency resonant objects tend to couple, while interacting weakly with other off-resonant environmental objects. The purpose of the invention is to quantify this mechanism using specific examples, namely quantitatively address the following questions: up to which distances can such a scheme be efficient and how sensitive is it to external perturbations. Detailed theoretical and numerical analysis show that a mid-range (L TRANS ≈few*L DEV ) wireless energy-exchange can actually be achieved, while suffering only modest transfer and dissipation of energy into other off-resonant objects.
[0035] The omnidirectional but stationary (non-lossy) nature of the near field makes this mechanism suitable for mobile wireless receivers. It could therefore have a variety of possible applications including for example, placing a source connected to the wired electricity network on the ceiling of a factory room, while devices, such as robots, vehicles, computers, or similar, are roaming freely within the room. Other possible applications include electric-engine buses, RFIDs, and perhaps even nano-robots. Similarly, in some embodiments multiple sources can transfer energy to one or more device objects. For example, as explained at in the paragraph bridging pages 4-5 of U.S. Provisional Application No. 60/698,442 to which the present application claims benefit and which is incorporated by reference above, for certain applications having uneven power transfer to the device object as the distance between the device and the source changes, multiple sources can be strategically placed to alleviate the problem, and/or the peak amplitude of the source can be dynamically adjusted.
[0036] The range and rate of the inventive wireless energy-transfer scheme are the first subjects of examination, without considering yet energy drainage from the system for use into work. An appropriate analytical framework for modeling the exchange of energy between resonant objects is a weak-coupling approach called “coupled-mode theory”. FIG. 1 is a schematic diagram illustrating a general description of the invention. The invention uses a source and device to perform energy transferring. Both the source 1 and device 2 are resonator structures, and are separated a distance D from each other. In this arrangement, the electromagnetic field of the system of source 1 and device 2 is approximated by F(r,t)≈a 1 (t)F 1 (r)+a 2 (t)F 2 (r), where F 1,2 (r)=[E 1,2 (r) H 1,2 (r)] are the eigenmodes of source 1 and device 2 alone, and then the field amplitudes a 1 (t) and a 2 (t) can be shown to satisfy the “coupled-mode theory”:
[0000]
a
1
t
=
-
i
(
ω
1
-
i
Γ
1
)
a
1
+
i
κ
11
a
1
+
i
κ
12
a
2
a
2
t
=
-
i
(
ω
2
-
i
Γ
2
)
a
2
+
i
κ
22
a
2
+
i
κ
21
a
1
,
(
1
)
[0000] where ω 1,2 are the individual eigen-frequencies, Γ 1,2 are the resonance widths due to the objects' intrinsic (absorption, radiation etc.) losses, κ 12,21 are the coupling coefficients, and κ 11,22 model the shift in the complex frequency of each object due to the presence of the other.
[0037] The approach of Eq. 1 has been shown, on numerous occasions, to provide an excellent description of resonant phenomena for objects of similar complex eigen-frequencies (namely |ω 1 -ω 2 |<<|κ 12,21 | and Γ 1 ≈Γ 2 ), whose resonances are reasonably well defined (namely Γ 1,2 & Im{κ 11,22 }<<|κ 12,21 |) and in the weak coupling limit (namely |κ 12,21 |<<ω 1,2 ). Coincidentally, these requirements also enable optimal operation for energy transfer. Also, Eq. (1) show that the energy exchange can be nearly perfect at exact resonance (ω 1 =ω 2 and Γ 1 =Γ 2 ), and that the losses are minimal when the “coupling-time” is much shorter than all “loss-times”. Therefore, the invention requires resonant modes of high Q=ω/(2Γ) for low intrinsic-loss rates Γ 1,2 , and with evanescent tails significantly longer than the characteristic sizes L 1 and L 2 of the two objects for strong coupling rate |κ 12,21 | over large distances D, where D is the closest distance between the two objects. This is a regime of operation that has not been studied extensively, since one usually prefers short tails, to minimize interference with nearby devices.
[0038] Objects of nearly infinite extent, such as dielectric waveguides, can support guided modes whose evanescent tails are decaying exponentially in the direction away from the object, slowly if tuned close to cutoff, and can have nearly infinite Q. To implement the inventive energy-transfer scheme, such geometries might be suitable for certain applications, but usually finite objects, namely ones that are topologically surrounded everywhere by air, are more appropriate.
[0039] Unfortunately, objects of finite extent cannot support electromagnetic states that are exponentially decaying in all directions in air, since in free space: {right arrow over (k)} 2 =ω 2 /c 2 . Because of this, one can show that they cannot support states of infinite Q. However, very long-lived (so-called “high-Q”) states can be found, whose tails display the needed exponential-like decay away from the resonant object over long enough distances before they turn oscillatory (radiative). The limiting surface, where this change in the field behavior happens, is called the “radiation caustic”, and, for the wireless energy-transfer scheme to be based on the near field rather than the far/radiation field, the distance between the coupled objects must be such that one lies within the radiation caustic of the other.
[0040] The invention is very general and any type of resonant structure satisfying the above requirements can be used for its implementation. As examples and for definiteness, one can choose to work with two well-known, but quite different electromagnetic resonant systems: dielectric disks and capacitively-loaded conducting-wire loops. Even without optimization, and despite their simplicity, both will be shown to exhibit fairly good performance. Their difference lies mostly in the frequency range of applicability due to practical considerations, for example, in the optical regime dielectrics prevail, since conductive materials are highly lossy.
[0041] Consider a 2D dielectric disk cavity of radius r and permittivity & surrounded by air that supports high-Q whispering-gallery modes, as shown in FIG. 2A . Such a cavity is studied using both analytical modeling, such as separation of variables in cylindrical coordinates and application of boundary conditions, and detailed numerical finite-difference-time-domain (FDTD) simulations with a resolution of 30 pts/r. Note that the physics of the 3D case should not be significantly different, while the analytical complexity and numerical requirements would be immensely increased. The results of the two methods for the complex eigen-frequencies and the field patterns of the so-called “leaky” eigenmodes are in an excellent agreement with each other for a variety of geometries and parameters of interest.
[0042] The radial modal decay length, which determines the coupling strength κ≡|κ 21 |=|κ 12 |, is on the order of the wavelength, therefore, for near-field coupling to take place between cavities whose distance is much larger than their size, one needs subwavelength-sized resonant objects (r<<λ). High-radiation-Q and long-tailed subwavelength resonances can be achieved, when the dielectric permittivity ε is as large as practically possible and the azimuthal field variations (of principal number m) are slow (namely m is small).
[0043] One such TE-polarized dielectric-cavity mode, which has the favorable characteristics Q rad =1992 and λ/r=20 using ε=147.7 and m=2 , is shown in FIG. 2A , and will be the “test” cavity 18 for all subsequent calculations for this class of resonant objects. Another example of a suitable cavity has Q rad =9100 and λ/r=10 using ε=65.61 and m=3 . These values of c might at first seem unrealistically large. However, not only are there in the microwave regime (appropriate for meter-range coupling applications) many materials that have both reasonably high enough dielectric constants and low losses, for example, Titania: ε≈96, Im{ε}/ε≈10 −3 ; Barium tetratitanate: ε≈37, Im{ε}/ε≈10 −4 ; Lithium tantalite: ε≈40, Im{ε}/ε≈10 −4 ; etc.), but also ε could instead signify the effective index of other known subwavelength (λ/r>>1) surface-wave systems, such as surface-plasmon modes on surfaces of metal-like (negative-ε) materials or metallodielectric photonic crystals.
[0044] With regards to material absorption, typical loss tangents in the microwave (e.g. those listed for the materials above) suggest that Q abs ˜ε/Im{ε}˜10000. Combining the effects of radiation and absorption, the above analysis implies that for a properly designed resonant device-object d a value of Q d ˜2000 should be achievable. Note though, that the resonant source s will in practice often be immobile, and the restrictions on its allowed geometry and size will typically be much less stringent than the restrictions on the design of the device; therefore, it is reasonable to assume that the radiative losses can be designed to be negligible allowing for Q s ˜10000, limited only by absorption.
[0045] To calculate now the achievable rate of energy transfer, one can place two of the cavities 20 , 22 at distance D between their centers, as shown in FIG. 2B . The normal modes of the combined system are then an even and an odd superposition of the initial modes and their frequencies are split by the coupling coefficient κ, which we want to calculate. Analytically, coupled-mode theory gives for dielectric objects κ 12 =ω 2 /2·∫d 3 rE* 1 (r)E 2 (r)ε 1 (r)/∫d 3 r|E 1 (r)| 2 ε(r), where ε 1,2 (r) denote the dielectric functions of only object 1 alone or 2 alone excluding the background dielectric (free space) and ε(r) the dielectric function of the entire space with both objects present. Numerically, one can find κusing FDTD simulations either by exciting one of the cavities and calculating the energy-transfer time to the other or by determining the split normal-mode frequencies. For the “test” disk cavity the radius r C of the radiation caustic is r C ≈11r, and for non-radiative coupling D<r C , therefore here one can choose D/r=10, 7, 5, 3. Then, for the mode of FIG. 3 , which is odd with respect to the line that connects the two cavities, the analytical predictions are ω/2κ=1602, 771, 298, 48, while the numerical predictions are ω/2κ=1717, 770, 298, 47 respectively, so the two methods agree well. The radiation fields of the two initial cavity modes interfere constructively or destructively depending on their relative phases and amplitudes, leading to increased or decreased net radiation loss respectively, therefore for any cavity distance the even and odd normal modes have Qs that are one larger and one smaller than the initial single-cavity Q=1992 (a phenomenon not captured by coupled-mode theory), but in a way that the average Γ is always approximately Γ≈ω/2Q. Therefore, the corresponding coupling-to-loss ratios are κ/Γ=1.16, 2.59, 6.68, 42.49, and although they do not fall in the ideal operating regime κ/Γ>>1, the achieved values are still large enough to be useful for applications.
[0046] Consider a loop 10 or 12 of N coils of radius r of conducting wire with circular cross-section of radius a surrounded by air, as shown in FIG. 3 . This wire has inductance L=μ o N 2 r[ ln(8r/a)−2], where μ o is the magnetic permeability of free space, so connecting it to a capacitance C will make the loop resonant at frequency ω=1/√{square root over (LC)}. The nature of the resonance lies in the periodic exchange of energy from the electric field inside the capacitor due to the voltage across it to the magnetic field in free space due to the current in the wire. Losses in this resonant system consist of ohmic loss inside the wire and radiative loss into free space.
[0047] For non-radiative coupling one should use the near-field region, whose extent is set roughly by the wavelength λ, therefore the preferable operating regime is that where the loop is small (r<<λ). In this limit, the resistances associated with the two loss channels are respectively R ohm =√{square root over (μ o ρω/2)}·Nr/a and R rad =π/6·η o N 2 (ωr/c) 4 , where ρ is the resistivity of the wire material and η o ≈120 πΩ is the impedance of free space. The quality factor of such a resonance is then Q=ωL/(R ohm +R rad ) and is highest for some frequency determined by the system parameters: at lower frequencies it is dominated by ohmic loss and at higher frequencies by radiation.
[0048] To get a rough estimate in the microwave, one can use one coil (N=1) of copper (ρ=1.69·10 −8 Ωm) wire and then for r=1 cm and a=1 mm, appropriate for example for a cell phone, the quality factor peaks to Q=1225 at f=380 MHz, for r=30 cm and a=2 mm for a laptop or a household robot Q=1103 at f=17 MHz, while for r=1 m and a=4 mm (that could be a source loop on a room ceiling) Q=1315 at f=5 MHz. So in general, expected quality factors are Q≈1000-1500 at λ/r≈50-80, namely suitable for near-field coupling.
[0049] The rate for energy transfer between two loops 10 and 12 at distance D between their centers, as shown in FIG. 3 , is given by κ 12 =ωM/2√{square root over (L 1 L 2 )}, where M is the mutual inductance of the two loops 10 and 12 . In the limit r<<D<<λ one can use the quasi-static result M=π/4·μ o N 1 N 2 (r 1 r 2 ) 2 /D 3 , which means that ω/2κ˜(D/√{square root over (r 1 r 2 )}) 3 . For example, by choosing again D/r=10, 8, 6 one can get for two loops of r=1 cm, same as used before, that ω/2κ=3033, 1553, 655 respectively, for the r=30 cm that ω/2κ=7131, 3651, 1540, and for the r=1 m that ω/2κ=6481, 3318, 1400. The corresponding coupling-to-loss ratios peak at the frequency where peaks the single-loop Q and are κ/Γ=0.4, 0.79, 1.97 and 0.15, 0.3, 0.72 and 0.2, 0.4, 0.94 for the three loop-kinds and distances. An example of dissimilar loops is that of a r=1 m (source on the ceiling) loop and a r=30 cm (household robot on the floor) loop at a distance D=3 m (room height) apart, for which κ/√{square root over (Γ 1 Γ 2 )}=0.88 peaks at f=6.4 MHz, in between the peaks of the individual Q's. Again, these values are not in the optimal regime κ/Γ>>1, but will be shown to be sufficient.
[0050] It is important to appreciate the difference between this inductive scheme and the already used close-range inductive schemes for energy transfer in that those schemes are non-resonant. Using coupled-mode theory it is easy to show that, keeping the geometry and the energy stored at the source fixed, the presently proposed resonant-coupling inductive mechanism allows for Q approximately 1000 times more power delivered for work at the device than the traditional non-resonant mechanism, and this is why mid-range energy transfer is now possible. Capacitively-loaded conductive loops are actually being widely used as resonant antennas (for example in cell phones), but those operate in the far-field regime with r/λ˜1, and the radiation Q's are intentionally designed to be small to make the antenna efficient, so they are not appropriate for energy transfer.
[0051] Clearly, the success of the inventive resonance-based wireless energy-transfer scheme depends strongly on the robustness of the objects' resonances. Therefore, their sensitivity to the near presence of random non-resonant extraneous objects is another aspect of the proposed scheme that requires analysis. The interaction of an extraneous object with a resonant object can be obtained by a modification of the coupled-mode-theory model in Eq. (1), since the extraneous object either does not have a well-defined resonance or is far-off-resonance, the energy exchange between the resonant and extraneous objects is minimal, so the term κ 12 in Eq. (1) can be dropped. The appropriate analytical model for the field amplitude in the resonant object a 1 (t) becomes:
[0000]
a
1
t
=
-
i
(
ω
1
-
i
Γ
1
)
a
1
+
i
κ
11
a
1
(
2
)
[0052] Namely, the effect of the extraneous object is just a perturbation on the resonance of the resonant object and it is twofold: First, it shifts its resonant frequency through the real part of Kul thus detuning it from other resonant objects. As shown in FIG. 7 , this This is a problem that can be fixed rather easily by applying a feedback mechanism 710 to every device (e.g., device resonators 720 and 730 ) that corrects its frequency, such as through small changes in geometry, and matches it to that of the source resonator 740 . Second, it forces the resonant object to lose modal energy due to scattering into radiation from the extraneous object through the induced polarization or currents in it, and due to material absorption in the extraneous object through the imaginary part of κ 11 . This reduction in Q can be a detrimental effect to the functionality of the energy-transfer scheme, because it cannot be remedied, so its magnitude must be quantified.
[0053] In the first example of resonant objects that have been considered, the class of dielectric disks, small, low-index, low-material-loss or far-away stray objects will induce small scattering and absorption. To examine realistic cases that are more dangerous for reduction in Q, one can therefore place the “test” dielectric disk cavity 40 close to: a) another off-resonance object 42 , such as a human being, of large Re{ε}=49 and Im{ε}=16 and of same size but different shape, as shown in FIG. 4A ; and b) a roughened surface 46 , such as a wall, of large extent but of small Re{ε}=2.5 and Im{ε}=0.05, as shown in FIG. 4B .
[0054] Analytically, for objects that interact with a small perturbation the reduced value of radiation-Q due to scattering could be estimated using the polarization ∫d 3 r|P X1 (r)| 2 ∝∫d 3 r|E 1 (r)·Rc{ε X (r)}| 2 induced by the resonant cavity 1 inside the extraneous object X=42 or roughened surface X=46. Since in the examined cases either the refractive index or the size of the extraneous objects is large, these first-order perturbation-theory results would not be accurate enough, thus one can only rely on numerical FDTD simulations. The absorption-Q inside these objects can be estimated through Im{κ 11 }=ω 1 /2·∫d 3 r|E 1 (r)| 2 Im{ε X (r)}/∫d 3 r|E 1 (r)| 2 ε(r).
[0055] Using these methods, for distances D/r=10, 7, 5, 3 between the cavity and extraneous-object centers one can find that Q rad =1992 is respectively reduced to Q rad =1988, 1258, 702, 226, and that the absorption rate inside the object is Q abs =312530, 86980, 21864, 1662, namely the resonance of the cavity is not detrimentally disturbed from high-index and/or high-loss extraneous objects, unless the (possibly mobile) object comes very close to the cavity. For distances D/r=10, 7, 5, 3, 0 of the cavity to the roughened surface we find respectively Q rad =2101, 2257, 1760, 1110, 572, and Q abs >4000, namely the influence on the initial resonant mode is acceptably low, even in the extreme case when the cavity is embedded on the surface. Note that a close proximity of metallic objects could also significantly scatter the resonant field, but one can assume for simplicity that such objects are not present.
[0056] Imagine now a combined system where a resonant source-object s is used to wirelessly transfer energy to a resonant device-object d but there is an off-resonance extraneous-object e present. One can see that the strength of all extrinsic loss mechanisms from e is determined by |E s (r e )| 2 , by the square of the small amplitude of the tails of the resonant source, evaluated at the position r e of the extraneous object. In contrast, the coefficient of resonant coupling of energy from the source to the device is determined by the same-order tail amplitude |E s (r d )|, evaluated at the position r d of the device, but this time it is not squared! Therefore, for equal distances of the source to the device and to the extraneous object, the coupling time for energy exchange with the device is much shorter than the time needed for the losses inside the extraneous object to accumulate, especially if the amplitude of the resonant field has an exponential-like decay away from the source. One could actually optimize the performance by designing the system so that the desired coupling is achieved with smaller tails at the source and longer at the device, so that interference to the source from the other objects is minimal.
[0057] The above concepts can be verified in the case of dielectric disk cavities by a simulation that combines FIGS. 2A-2B and 4 A- 4 B, namely that of two (source-device) “test” cavities 50 placed 10 r apart, in the presence of a same-size extraneous object 52 of ε=49 between them, and at a distance 5 r from a large roughened surface 56 of ε=2.5, as shown in FIG. 5 . Then, the original values of Q=1992, ω/2κ=1717 (and thus κ/Γ=1.16) deteriorate to Q=765, ω/2κ=965 (and thus κ/Γ=0.79). This change is acceptably small, considering the extent of the considered external perturbation, and, since the system design has not been optimized, the final value of coupling-to-loss ratio is promising that this scheme can be useful for energy transfer.
[0058] In the second example of resonant objects being considered, the conducting-wire loops, the influence of extraneous objects on the resonances is nearly absent. The reason for this is that, in the quasi-static regime of operation (r<<λ) that is being considered, the near field in the air region surrounding the loop is predominantly magnetic, since the electric field is localized inside the capacitor. Therefore, extraneous objects that could interact with this field and act as a perturbation to the resonance are those having significant magnetic properties (magnetic permeability Re{μ}>1 or magnetic loss Im{μ}>0). Since almost all common materials are non-magnetic, they respond to magnetic fields in the same way as free space, and thus will not disturb the resonance of a conducting-wire loop. The only perturbation that is expected to affect these resonances is a close proximity of large metallic structures.
[0059] An extremely important implication of the above fact relates to safety considerations for human beings. Humans are also non-magnetic and can sustain strong magnetic fields without undergoing any risk. This is clearly an advantage of this class of resonant systems for many real-world applications. On the other hand, dielectric systems of high (effective) index have the advantages that their efficiencies seem to be higher, judging from the larger achieved values of κ/Γ, and that they are also applicable to much smaller length-scales, as mentioned before.
[0060] Consider now again the combined system of resonant source s and device d in the presence of a human h and a wall, and now let us study the efficiency of this resonance-based energy-transfer scheme, when energy is being drained from the device for use into operational work. One can use the parameters found before: for dielectric disks, absorption-dominated loss at the source Q s ˜10 4 , radiation-dominated loss at the device Q d ˜10 3 (which includes scattering from the human and the wall), absorption of the source- and device-energy at the human Q s-h , Q d-h ˜10 4 -10 5 depending on his/her not-very-close distance from the objects, and negligible absorption loss in the wall; for conducting-wire loops, Q s ˜Q d 10 3 , and perturbations from the human and the wall are negligible. With corresponding loss-rates Γ=ω/2Q, distance-dependent coupling κ, and the rate at which working power is extracted Γ w , the coupled-mode-theory equation for the device field-amplitude is
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[0061] Different temporal schemes can be used to extract power from the device and their efficiencies exhibit different dependence on the combined system parameters. Here, one can assume steady state, such that the field amplitude inside the source is maintained constant, namely a s (t)=A s e −iωt , so then the field amplitude inside the device is a d (t)=A d e −iωt with A d =iκ/(Γ d +Γ d-h +Γ w )A s . Therefore, the power lost at the source is P s =2Γ s |A s | 2 , at the device it is P d =2Γ d |A d | 2 , the power absorbed at the human is P h =2Γ s-h |A s | 2 +2Γ d-h |A d | 2 , and the useful extracted power is P w =2Γ w |A d | 2 . From energy conservation, the total power entering the system is P total =P s +P d +P h +P w . Denote the total loss-rates Γ s tot =Γ s +Γ s-h and Γ d tot =Γ d +Γ d-h . Depending on the targeted application, the work-drainage rate should be chosen either Γ w =Γ d tot to minimize the required energy stored in the resonant objects or Γ w =Γ d tot √{square root over (1+κ 2 /Γ s tot Γ d tot )}>Γ d tot such that the ratio of useful-to-lost powers, namely the efficiency η w =P w /P total , is maximized for some value of κ. The efficiencies η for the two different choices are shown in FIGS. 6A and 6B respectively, as a function of the κ/Γ d figure-of-merit which in turn depends on the source-device distance.
[0062] FIGS. 6A-6B show that for the system of dielectric disks and the choice of optimized efficiency, the efficiency can be large, e.g., at least 40%. The dissipation of energy inside the human is small enough, less than 5%, for values κ/Γ d >1 and Q h >10 5 , namely for medium-range source-device distances (D d /r<10) and most human-source/device distances (D h /r>8). For example, for D d /r=10 and D h /r=8, if 10 W must be delivered to the load, then, from FIG. 6B , ˜0.4 W will be dissipated inside the human, ˜4 W will be absorbed inside the source, and ˜2.6 W will be radiated to free space. For the system of conducting-wire loops, the achieved efficiency is smaller, ˜20% for κ/Γ d ≈1, but the significant advantage is that there is no dissipation of energy inside the human, as explained earlier.
[0063] Even better performance should be achievable through optimization of the resonant object designs. Also, by exploiting the earlier mentioned interference effects between the radiation fields of the coupled objects, such as continuous-wave operation at the frequency of the normal mode that has the larger radiation-Q, one could further improve the overall system functionality. Thus the inventive wireless energy-transfer scheme is promising for many modern applications. Although all considerations have been for a static geometry, all the results can be applied directly for the dynamic geometries of mobile objects, since the energy-transfer time κ −1 ˜1 μs, which is much shorter than any timescale associated with motions of macroscopic objects.
[0064] The invention provides a resonance-based scheme for mid-range wireless non-radiative energy transfer. Analyses of very simple implementation geometries provide encouraging performance characteristics for the potential applicability of the proposed mechanism. For example, in the macroscopic world, this scheme could be used to deliver power to robots and/or computers in a factory room, or electric buses on a highway (source-cavity would in this case be a “pipe” running above the highway). In the microscopic world, where much smaller wavelengths would be used and smaller powers are needed, one could use it to implement optical inter-connects for CMOS electronics or else to transfer energy to autonomous nano-objects, without worrying much about the relative alignment between the sources and the devices; energy-transfer distance could be even longer compared to the objects' size, since Im{ε(ω)} of dielectric materials can be much lower at the required optical frequencies than it is at microwave frequencies.
[0065] As a venue of future scientific research, different material systems should be investigated for enhanced performance or different range of applicability. For example, it might be possible to significantly improve performance by exploring plasmonic systems. These systems can often have spatial variations of fields on their surface that are much shorter than the free-space wavelength, and it is precisely this feature that enables the required decoupling of the scales: the resonant object can be significantly smaller than the exponential-like tails of its field. Furthermore, one should also investigate using acoustic resonances for applications in which source and device are connected via a common condensed-matter object.
[0066] Although the present invention has been shown and described with respect to several preferred embodiments thereof, various changes, omissions and additions to the form and detail thereof, may be made therein, without departing from the spirit and scope of the invention. | Described herein are embodiments of a source high-Q resonator, optionally coupled to an energy source, a second high-Q resonator, optionally coupled to an energy drain that may be located a distance from the source resonator. A third high-Q resonator, optionally coupled to an energy drain that may be located a distance from the source resonator. The source resonator and at least one of the second resonator and third resonator may be coupled to transfer electromagnetic energy from said source resonator to said at least one of the second resonator and third resonator. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation of Application PCT/JP2007/065827, filed on Aug. 13, 2007, the entire contents of which are incorporated herein by reference.
FIELD
A certain aspect of the embodiments discussed herein relates to a technique of assessing a voice communication quality of a communication path.
BACKGROUND
Networks are shifting from current circuit switching networks to packet exchange networks, and Next Generation Network (NGN) representing such shift has been established. The NGN is configured to implement voice communication using the network while maintaining voice communication quality equivalent to the quality of the current circuit switching networks and so on.
Thus, it is more important to estimate voice communication quality in a next generation network represented by the NGN, and measurement technology for evaluating voice communication quality on a middle path and a terminal of the network is required. That is, technology for testing voice quality degradation used for estimating the voice communication quality from data being transferred is necessary. In particular, technology for analyzing data during operation, i.e., so called active measurement technology is required.
Japanese Laid-open Patent Publication No. 2000-332758 and Japanese Laid-open Patent Publication No. 07-250107 disclose technology for estimating voice quality.
SUMMARY
According to an aspect of an embodiment, a system for assessing a voice communication quality of a communication path between first and second nodes over a network, wherein coded data of voice communication signals are transferred in a stream of packets via the communication path, the system includes: a capturing unit for capturing at the first node at least one packet containing coded data representing non voice signals among the packets of the coded data to be transferred from the first node to the second node; a replacing unit for replacing a part of the coded data representing non voice signals in the captured packet with a predetermined code before the captured packet is transferred from the first node; a retrieval unit for retrieving at the second node said at least one packet containing coded data representing non voice signals transferred from the first node; and an assessment unit for assessing the voice communication quality of the communication path on the basis of detection of the predetermined code in the retrieved packet.
The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 illustrates a network system of the embodiment configured to test voice quality degradation.
FIG. 2 is a schematic diagram of an analog signal of the embodiment.
FIG. 3 is a schematic diagram of a code of the embodiment.
FIG. 4 is a block diagram of a pattern replacement unit of the embodiment.
FIG. 5 is a block diagram of a pattern test unit of the embodiment.
FIG. 6 is a flowchart of a process performed by the pattern replacement unit of the embodiment.
FIG. 7 is a flowchart of a process performed by the pattern test unit of the embodiment.
FIG. 8 is a block diagram of a pattern replacement unit of the embodiment.
FIG. 9 is a block diagram of a test unit of the embodiment.
FIG. 10 is a flowchart of a process performed by the pattern test unit of the embodiment.
DESCRIPTION OF EMBODIMENTS
FIG. 1 illustrates a network system 100 of the embodiment configured to test voice quality degradation. According to the embodiment, a test for a voice quality degradation factor of the network system 100 will be explained hereafter. According to the test method of the embodiment, a factor of voice quality degradation caused by a change of data itself transferred by the network system 100 such as noise inserted in a quality controlled area 115 of the network system 100 can be detected while the network is being practically operated. Incidentally, operations of a pattern replacement unit 101 and pattern test units 102 and 103 will be explained in detail with reference to FIG. 4 and FIG. 5 .
[Configuration of Network System 100 ]
The network system 100 is constituted by the pattern replacement unit 101 , the pattern test units 102 and 103 , a detection identification unit 104 , a terminal adaptor (TA) 106 , a core edge (CE) 107 , gateways 108 and 109 , a terminal adaptor (TA) 110 and terminals 111 and 117 . According to the embodiment, a terminal 105 performs voice communication with the terminals 111 and 117 through a private network 112 , an access network 113 , a core network 114 and a public network 116 . Specifically, the network system 100 is a network system in which the terminal 105 obtains a voice signal as an interface, encodes the voice signal and transfers the voice signal to the terminals 111 and 117 in real time in an IP packet form and so on (VoIP: Voice over Internet Protocol).
The network system 100 is a network system configured to detect a problem that occurs in the quality controlled area 115 (the access network 113 and the core network 114 ) by using the pattern replacement unit 101 and the pattern test units 102 and 103 . The network system 100 of the embodiment can detect voice quality degradation caused by noise inserted in the quality controlled area 115 in the network. Further, the network system 100 of the embodiment can also detect voice quality degradation caused by transcoding such that a compression format of data is converted in the quality controlled area 115 in the network.
The pattern replacement unit 101 replaces a portion of a non-voice code to be sent to the quality controlled area 115 with a particular pattern. Then, the pattern test units 102 and 103 detect the particular pattern in the quality controlled area 115 . The detection identification unit 104 senses an involved factor of voice quality degradation from whether or not the particular pattern has been detected. The particular pattern of the embodiment is a code pattern that the pattern replacement unit 101 and the pattern test units 102 and 103 mutually hold, and is a code pattern that has been determined in advance. Further, the particular pattern is a code sequence having same weights of a plurality of code series.
Thus, the network system 100 can test a factor of voice quality degradation of data flowing through the quality controlled area 115 in the network system 100 even while the network is being practically operated. According to the test method of the embodiment, voice quality degradation caused by inserted noise that changes data itself can be detected as well as other voice quality degradation caused by a data delay or a packet loss.
The pattern replacement unit 101 is provided at the CE 107 , i.e., a point corresponding to an entrance to the quality controlled area 115 (the access network 113 and the core network 114 ). The pattern replacement unit 101 replaces a portion of a non-voice code with a particular pattern for sensing a problem. The non-voice code described here is a code corresponding to background noise included in a code that the terminal 105 produces by receiving a voice signal as an interface and encoding the received voice signal. Codec technology of the embodiment is, e.g., G. 711 recommended by ITU-T. Thus, an analog voice signal received by the terminal 105 is encoded in accordance with G. 711. The TA 106 encodes and decodes (codec) the analog voice signal. The terminals 105 , 111 and 117 may be configured to encode and decode the analog voice signal into a digital voice signal. The encoding technology according to G. 711 recommended by ITU-T is a system for implementing a data rate of 64 kbps on a telephone line by using a PCM (pulse code modulation) system. Specifically, the analog signal is sampled at 8 kHz (sampling), and every sample is represented in 8 bits.
The pattern replacement unit 101 takes in a code 300 transferred by the network system 100 through the CE 107 every frame of 20 msec including 160 samples. Then, the pattern replacement unit 101 analyzes a voice characteristic of the code 300 , and detects a non-voice frame. The voice characteristic indicates data classifying every frame of the code 300 into a voice frame and a non-voice frame. Specifically, the voice characteristic is formed by a number of zero-crossings and an amplitude level. The number of zero-crossings represents how many times a voice waveform crosses a zero level in a certain period of time. The amplitude level is an average amplitude value of each of data 310 - 318 in a certain period of time. The pattern replacement unit 101 identifies a frame of a data amplitude level being equal to or greater than a certain value and of a number of zero-crossings being equal to or smaller than a certain number in a certain period of time as a voice frame. Then, the pattern replacement unit 101 identifies a frame other than the voice frame as a non-voice frame.
Further, the pattern replacement unit 101 analyzes a characteristic of a frame identified as a non-voice frame. The pattern replacement unit 101 detects a background noise level from the characteristic analysis. Then, the pattern replacement unit 101 replaces a portion of a level range lower than or around the detected background noise level of the detected non-voice frame with a particular pattern. The level described here is an amplitude value when one sample of an analog signal is encoded to 8-bit data in accordance to G. 711. The less significant digit and the more significant digit of the 8-bit data indicate portions of the smaller and greater amplitude values, respectively.
The pattern replacement unit 101 does not perform a particular pattern replacement process for a silent frame. The silent frame is a frame such that frame data includes all zero bits or at most bits indicating a faint sound of a value equal to or lower than a certain threshold. A reason why is that replacement of a portion of the silent frame with the particular pattern affects subjective sound quality a lot. Thus, as a portion of the silent frame is not replaced with the particular pattern, the pattern replacement unit 101 can prevent noise from being inserted by using a masking effect (refer to Wegel, R. L. and Lane, C. E.: Phys. Rev., 23, pp. 266-285 (1924)).
According to the test method of the embodiment, the pattern replacement unit 101 replaces a portion of a non-voice code with the particular pattern. Thus, an amount of data that flows through the network system 100 does not increase. Hence, according to the test method of the embodiment, a traffic increase in the network caused by the test for voice quality degradation can be removed. That is, the test method of the embodiment enables the voice quality degradation to be tested without causing ill effects such as a traffic increase in the network and resultant congestion.
The pattern test units 102 and 103 are provided at the GWs 108 and 109 , respectively. The pattern test units 102 and 103 take in the code 300 transferred by the network system 100 through the GWs 108 and 109 , respectively, every frame of 20 msec including 160 samples. The pattern test units 102 and 103 choose a non-voice frame as a frame to be tested. A reason why is that the pattern replacement unit 101 performs a replacement process with the particular pattern for a non-voice frame. The pattern test units 102 and 103 detect a background noise level from a characteristic analysis of a frame identified as a non-voice frame. The pattern test units 102 and 103 refer to the background noise level, and examine whether or not the particular pattern exists in a frame to be tested of a level lower than or around the background noise level. The pattern test units 102 and 103 can thereby efficiently detect the particular pattern. A reason why is that a replacement position of the particular pattern is of a level equal to or lower than the background noise level of the frame to be tested.
Then, the pattern test units 102 and 103 send existence data indicating whether or not the particular pattern exists to the detection identification unit 104 . The detection identification unit 104 detects a problem and estimates where the problem occurs from the existence data. Specifically, in a case where the non-voice frame for which the pattern replacement unit 101 has performed the replacement process includes a particular pattern, the detection identification unit 104 identifies no occurrence of voice quality degradation. Meanwhile, in a case where the particular pattern does not exist in the non-voice frame for which the pattern replacement unit 101 has performed the replacement process, the detection identification unit 104 identifies an occurrence of voice quality degradation. The detection identification unit 104 can make the above identification by comparing data of a replacement-processed non-voice frame that the detection identification unit 104 has ready beforehand and the existence data. That is, in a case where the existence data of a non-voice frame expected to include the particular pattern indicates “no particular pattern”, the detection identification unit 104 identifies an occurrence of voice quality degradation. Thus, the detection identification unit 104 obtains existence data of a particular pattern 319 from the pattern test units 102 and 103 , and can test existence of an occurrence of voice quality degradation of data that flows through the quality controlled area 115 in the network system 100 . Further, the detection identification unit 104 can estimate a position of the occurrence of the voice quality degradation by analyzing where the pattern test units 102 and 103 are provided.
[Analog Signal 200 , Code 300 ]
FIG. 2 illustrates a schematic diagram of an analog signal 200 of the embodiment. The terminal 105 sends the code 300 into which the analog signal 200 is digitized to the terminals 111 and 117 . The code 300 into which the analog signal 200 is digitized is to be tested with respect to the voice quality degradation.
The TA 106 of the embodiment illustrated in FIG. 1 encodes the analog signal 200 into the code 300 . The TA 106 of the embodiment samples the analog signal 200 with a desired frequency. Specifically, the TA 106 samples the analog signal 200 as 21-38. Then, the TA 106 quantizes and thereby encodes amplitude values of 21-38 into data 301 - 318 , respectively. The TA 106 of the embodiment sends the code to the network as frames of 160 samples each. That is, one frame to be sent includes 160 samples.
FIG. 3 illustrates a schematic diagram of the code 300 corresponding to the analog signal 200 . The code 300 is formed by the data 301 - 318 . Although one frame includes 160 samples as described above, FIG. 3 typically illustrates nine samples per one frame (data 301 - 309 and data 310 - 318 ). The data 301 is an amplitude value of a quantized and digitally encoded sampling value 21. Further, the data 302 is an encoded 22 . The data (300+n) is similarly an encoded (20+n) (n is a natural number of 1-18). Encoding technology of the embodiment is G. 711. G. 711 is a waveform encoding method of analog voice data recommended by ITU-T. The sampling rate (sampling speed) is 8 kHz. The data 301 - 318 are in 8 bits each. The data 301 of the sampling 21 is, e.g., “10101111”. The data 302 of the sampling 22 is “00110001”. The data 303 of the sampling 23 is “10111000”. The other following data 304 - 318 are in 8 bits each. The data 301 - 318 are in 8 bits each. First bits of the data 301 - 318 represent a portion of a great amplitude of the samplings 21 - 38 , respectively. Second, third and other bits are data indicating portions of small amplitudes in the above order. One frame is formed by 160 data (samples) of the data 301 - 309 . The network system 100 of the embodiment transfers data every frame (160 samples).
Two kinds of quantization methods, μ-Law and A-Law, are specified. The methods, μ-Law and A-Law, are one of encoding laws for converting an analog signal into a digital signal by using PCM (pulse code modulation) each. Further, G. 711 is one of simplest methods for waveform encoding called PCM (pulse code modulation). An amplitude value of each of samples sampled at 8 kHz is quantized into a discrete value of 256 (8 bit) levels. At that moment, as amplitude distribution of a voice signal illustrates exponential distribution, quantized bits can be made appear equally frequently to one another by logarithmic conversion so that distortion can be minimized. That is, a value of a small amplitude is quantized with a fine step width, and a value of a great amplitude is quantized with a coarse step width. According to G. 711, two kinds of equations, μ-law and A-law, are adopted as logarithmic conversion rules. According to G. 711, one of the conversion rules (e.g., μ-Law) is used so that the code 300 is produced.
According to the embodiment, the pattern replacement unit 101 replaces a portion of an area in the code 300 which corresponds to the non-voice signal 202 (the frame including the data 310 - 318 ) with the particular pattern 319 . As illustrated in FIG. 3 , the particular pattern 319 is “010110 . . . 011”. A position where the pattern replacement unit 101 replaces the particular pattern 319 can be fixed depending on the background noise level. The pattern replacement unit 101 can, e.g., render a portion of bit weight equal to or less than 320.
Then, the pattern test units 102 and 103 detect the particular pattern 319 replaced by the pattern replacement unit 101 . The detection identification unit 104 obtains the particular pattern 319 from the pattern test units 102 and 103 , and identifies whether or not voice quality degradation exists in the code 300 .
[Configuration of Pattern Replacement Unit 101 ]
FIG. 4 illustrates a block diagram of the pattern replacement unit 101 of the embodiment illustrated in FIG. 1 . Operation of the pattern replacement unit 101 will be explained below in detail with reference to FIG. 4 .
The pattern replacement unit 101 is constituted by a voice analysis unit 401 , an object frame selection unit 402 , a particular pattern replacement unit 403 and a detection use pattern saving unit 404 .
The voice analysis unit 401 takes in the code 300 illustrated in FIG. 3 from the CE 107 illustrated in FIG. 1 every frame of 20 msec including 160 samples. Then, the voice analysis unit 401 analyzes a voice characteristic of the code 300 that has been taken in. The voice characteristic is data that classifies every frame of the code 300 into a voice frame and a non-voice frame. Specifically, the voice characteristic is formed by a number of zero-crossings and an amplitude level. The number of zero-crossings represents how many times a voice waveform crosses a zero level in a certain period of time. The amplitude level is an average amplitude value of each of data 310 - 318 in a certain period of time. The voice analysis unit 401 identifies a frame of a data amplitude level being equal to or greater than a certain value and of a number of zero-crossings being equal to or smaller than a certain number in a certain period of time as a voice frame. In order to prevent portions of small amplitudes corresponding to a rise and a fall in voice from being clipped at a start and an end of a voice frame interval, respectively, the voice analysis unit 401 brings the start of the voice frame interval forward and puts the end of the voice frame interval off so as to severally give margins for identifying voice and non-voice frames.
The object frame selection unit 402 selects the non-voice frame that the voice analysis unit 401 has detected as a frame to be replaced with the particular pattern 319 . Why the object frame selection unit 402 does not cause a voice frame to be a frame to be replaced with the particular pattern 319 is for preventing the particular pattern 319 from causing noise. Meanwhile, a non-voice frame is in general background noise data. Thus, a partial change of a non-voice frame can hardly be sensed as voice quality degradation.
The particular pattern replacement unit 403 replaces a portion of the non-voice frame that the object frame selection unit 402 has selected with the particular pattern 319 . The particular pattern replacement unit 403 of the embodiment replaces a seventh bit of the non-voice frame with the particular pattern 319 (see FIG. 3 ). The seventh bit of the non-voice frame means a code sequence corresponding to the seventh row from the MSB (Most Significant Bit) of the G. 711 code (data 310 - 318 ) of the non-voice frame illustrated in FIG. 3 . That is, the data 310 - 318 are arranged in chronological order for the code 319 illustrated in FIG. 3 . And the particular pattern replacement unit 403 replaces the seventh row corresponding to a portion of a small amplitude of the non-voice signal 202 with the particular pattern 319 .
The voice analysis unit 401 performs an amplitude analysis of a frame identified as a non-voice frame, and determines a background noise level 320 . The amplitude analysis is a process by means of the voice analysis unit 401 for averaging amplitude values of non-voice frames for a certain period of time so as to cause the average value to be the background noise level. The particular pattern 319 is saved in the detection use pattern saving unit 404 . The particular pattern replacement unit 403 reads the particular pattern 319 from the detection use pattern saving unit 404 . Then, the particular pattern replacement unit 403 replaces a portion of a non-voice frame with the particular pattern 319 with reference to the background noise level 320 . That is, the particular pattern replacement unit 403 replaces the seventh row of the non-voice frame with the particular pattern 319 (“010110 . . . 011”). As a replacement position of the particular pattern 319 is equal to or lower than the background level, the particular pattern replacement unit 403 refers to the background noise level 320 . Further, the particular pattern replacement unit 403 does not perform a replacement process of the particular pattern 319 for a non-voice frame of volume imperceptible for a person.
[Processing Procedure of Pattern Replacement Unit 101 ]
FIG. 6 illustrates a flowchart of a process performed by the pattern replacement unit 101 . Further, FIG. 4 illustrates a configuration of the pattern replacement unit 101 . The process flowchart illustrated in FIG. 6 will be explained below with reference to the configuration of the pattern replacement unit 101 illustrated in FIG. 4 .
The voice analysis unit 401 takes in the code 300 illustrated in FIG. 3 every frame (160 samples) (step S 601 ).
The voice analysis unit 401 performs a voice analysis process on the code 300 from the voice characteristic of the code 300 that has been taken in (step S 602 ).
The voice analysis unit 401 identifies whether the frame that has been taken in is a voice frame or a non-voice frame in order from a result of the voice analysis process (step S 603 ). The voice analysis unit 401 identifies a frame of an amplitude level of the data forming the code 300 being equal to or greater than a certain value and of a number of zero-crossings being equal to or smaller than a certain number in a certain period of time as a voice frame, and identifies a frame other than that as a non-voice frame.
If the voice analysis unit 401 identifies the frame that has been taken in as a non-voice frame (step S 603 YES), the particular pattern replacement unit 403 fixes a position of the non-voice frame to be replaced with the particular pattern 319 (particular pattern replacement position) (step S 604 ). The particular pattern replacement unit 403 fixes the particular pattern replacement position with reference to the background noise level 320 . On this occasion, the voice analysis unit 401 determines the background noise level 320 . The particular pattern replacement unit 403 causes a code pattern in a level range equal to or lower than the background noise level to be replaced with the particular pattern. The code pattern is a combination of bits of samples illustrating a same amplitude level in a frame formed by a plurality of samples. In other words, the code pattern is a chain of codes having a same bit weight in a frame formed by a plurality of samples. A portion of the code pattern to be replaced is formed by a combination of the codes in a level range equal to or lower than the background noise level, and the one formed with respect to the amplitude level is an example.
The voice analysis unit 401 calculates an average value of amplitude values of a non-voice frame for a certain period of time, and causes the average value to be the background noise level. Further, the voice analysis unit 401 may be configured to calculate an average value of amplitude values of a past non-voice frame and to cause the average value to be the background noise level. The past non-voice frame means a non-voice frame existing chronologically ahead of the non-voice frame to be replaced with the particular pattern 319 . Further, the past non-voice frame is in other words a non-voice frame that the voice analysis unit 401 receives, and a non-voice frame that the voice analysis unit 401 receives before receiving the non-voice frame to be partially replaced with the particular pattern 319 . Further, the position of the non-voice frame to be replaced with the particular pattern 319 by the particular pattern replacement unit 403 (particular pattern replacement position) is a position of a code belonging to a level equal to or lower than the background noise level. The particular pattern replacement unit 403 replaces a code pattern that is a portion of a non-voice frame selected by the object frame selection unit 402 and of a level range equal to or lower than the background noise level (step S 605 ).
Further, if the voice analysis unit 401 identifies the frame as not being a non-voice frame (step S 603 NO), the pattern replacement unit 101 ends the replacement process.
[Configuration of Pattern Test Units 102 and 103 ]
FIG. 5 illustrates a block diagram of the pattern test unit 102 of the embodiment. The pattern test unit 102 is constituted by a voice analysis unit 501 , an object frame selection unit 502 , a pattern detection unit 503 and a detection use pattern saving unit 504 . Operation of the pattern test unit 102 will be explained below in detail with reference to FIG. 5 . The pattern test unit 103 has a same configuration and performs a same operation process as the pattern test unit 102 .
The voice analysis unit 501 takes in the code 300 illustrated in FIG. 3 from the GW 108 illustrated in FIG. 1 every frame of 20 msec including 160 samples. Then, the voice analysis unit 501 identifies whether the frame that has been taken in is a voice frame or a non-voice frame in order. Specifically, the voice analysis unit 501 analyzes a voice characteristic of the code 300 , and classifies every frame into a voice frame and a non-voice frame. In order to prevent portions of small amplitudes corresponding to a rise and a fall in voice from being clipped at a start and an end of a voice frame interval, respectively, the voice analysis unit 501 also brings the start of the voice frame interval forward and puts the end of the voice frame interval off so as to severally give margins for identifying voice and non-voice frames.
The object frame selection unit 502 selects the non-voice frame identified by the voice analysis unit 501 as a frame to be replaced with the particular pattern 319 . That is, an object to be tested by the pattern test unit 503 is a non-voice frame. The pattern test unit 503 does not test a voice frame.
The pattern detection unit 503 identifies whether or not the particular pattern 319 exists in the non-voice frame selected by the object frame selection unit 502 . The particular pattern to be detected by the pattern detection unit 503 is saved in the detection use pattern saving unit 504 . The pattern detection unit 503 reads the particular pattern saved in the detection use pattern saving unit 504 , and identifies whether or not the particular pattern exists in the non-voice frame while referring to the particular pattern. On this occasion, the voice analysis unit 501 performs an amplitude value analysis of the non-voice frame, and determines a background noise level. The pattern detection unit 503 identifies whether or not the particular pattern exists in the non-voice frame with reference to the background noise level. That is, the pattern detection unit 503 identifies whether or not the particular pattern exists in the level range equal to or lower than the background noise level. Thus, as the pattern detection unit 503 does not search a level range higher than the background noise level for the particular pattern, the particular pattern detection can be made more efficient.
The pattern detection unit 503 provides the detection identification unit 104 with pattern replacement existence data indicating whether or not the particular pattern exists in the tested non-voice frame.
[Process Procedure of Pattern Test Unit 102 ]
FIG. 7 illustrates a flowchart of a process performed by the pattern test unit 102 of the embodiment. The pattern test unit 102 detects the particular pattern 319 in the non-voice frame. The pattern test unit 103 performs a same process as the pattern test unit 102 . Further, FIG. 5 illustrates a configuration of the pattern test unit 102 . The process flowchart illustrated in FIG. 7 will be explained below with reference to the configuration of the pattern replacement unit 101 illustrated in FIG. 5 .
The voice analysis unit 501 takes in the code 300 from the GW 108 every frame of 20 msec including 160 samples (step S 701 ).
The voice analysis unit 501 performs a voice analysis process on the code 300 from the voice characteristic of the code 300 that has been taken in (step S 702 ).
The voice analysis unit 501 identifies whether the frame that has been taken in is a voice frame or a non-voice frame in order from a result of the voice analysis process (step S 703 ).
If the voice analysis unit 501 identifies the frame that has been taken in as a non-voice frame (step S 703 YES), the object frame selection unit 502 selects the non-voice frame as an object to be tested with respect to the particular pattern. Then, the pattern test unit 503 obtains the background noise level from the voice analysis unit 501 , and determines with reference to the background noise level a level range in which the particular pattern of the non-voice frame is tested (step S 704 ). Specifically, the level range in which the particular pattern is tested described above is a portion of the code pattern in the non-voice frame of a level equal to or lower than the background noise level. The level described here is an amplitude value when one sample of an analog signal is encoded to 8-bit data in accordance to G. The less significant digit and the more significant digit of the 8-bit data represent portions of the smaller and greater amplitude values, respectively.
The pattern detection unit 503 identifies whether or not the particular pattern 319 exists in a level range equal to or lower than the background noise level in the non-voice frame selected by the object frame selection unit 502 (step S 705 ). The particular pattern to be detected by the pattern detection unit 503 is saved in the detection use pattern saving unit 504 . The pattern detection unit 503 reads the particular pattern saved in the detection use pattern saving unit 504 , and identifies whether or not the particular pattern exists in the level range equal to or lower than the background noise level in the non-voice frame while referring to this particular pattern.
Upon identifying the particular pattern as existing in the non-voice frame (S 705 YES), the pattern detection unit 503 sends pattern replacement existence data indicating that the particular pattern exists in the non-voice frame to the detection identification unit 104 . What is described above means that the particular pattern with which the pattern replacement unit 101 has replaced a portion of the non-voice frame has not changed and has flown in the quality controlled area 115 , and illustrates that degradation of the sound quality of the code 300 has not occurred.
Upon identifying the particular pattern as not existing in the non-voice frame (step S 705 NO), the pattern detection unit 503 sends pattern replacement absence data indicating that no particular pattern exists in a non-silent frame to the detection identification unit 104 . What is described above means that the particular pattern with which the pattern replacement unit 101 has replaced a portion of the non-voice frame has changed and has flown in the quality controlled area 115 , and illustrates that a change such as degradation of the sound quality of the code 300 has occurred.
The pattern detection unit 503 provides the detection identification unit 104 with pattern replacement existence/absence data (indicating the pattern replacement existence data and the pattern replacement absence data) indicating whether or not the particular pattern exists in the tested non-voice frame.
Further, if the voice analysis unit 501 identifies the frame that has been taken in as a voice frame at the step S 703 (step S 703 NO), the pattern test unit 101 does not perform the replacement process of the particular pattern 319 .
[Configuration of Pattern Replacement Unit 800 ]
FIG. 8 illustrates a block diagram of a pattern replacement unit 800 of the embodiment. For a series of frames to be replaced and identified as non-voice frames, the pattern replacement unit 800 changes a position of each of the non-voice frames replaced with the particular pattern in accordance with a certain rule. For a series of the non-voice frames, the pattern replacement unit 800 of the embodiment causes a position at which an amplitude level periodically changes to be the particular pattern replacement position.
The pattern replacement unit 800 is constituted by a voice analysis unit 801 , an object frame selection unit 802 , a particular pattern replacement unit 803 and a detection use pattern saving unit 804 . Further, the particular pattern replacement unit 803 has a pattern position fixing unit 805 . The pattern position fixing unit 805 has a function of fixing particular pattern replacement positions of a series of non-voice frames in accordance with a certain rule.
The voice analysis unit 801 takes in the code 300 every frame of 20 msec including 160 samples. Where the voice analysis unit 801 takes in the frames is the CE 107 (CE: core edge) illustrated in FIG. 1 and so on. As a matter of course, a network device other than the core edge will do.
Then, the voice analysis unit 801 analyzes a voice characteristic of the code that has been taken in. The voice characteristic is data that identifies a voice frame and a non-voice frame of the code. Specifically, the voice characteristic is formed by a number of zero-crossings and an amplitude level. The number of zero-crossings represents how many times a voice waveform crosses a zero level in a certain period of time. The amplitude level is an average amplitude value of each of data 310 - 318 in a certain period of time. The voice analysis unit 801 identifies a frame of a data amplitude level being equal to or greater than a certain value and of a number of zero-crossings being equal to or smaller than a certain number in a certain period of time as a voice frame. Further, the voice analysis unit 801 identifies background noise from the amplitude level and the number of zero-crossings which are the voice characteristic of the data.
In order to prevent portions of small amplitudes corresponding to a rise and a fall in voice from being clipped at a start and an end of a voice frame interval, respectively, the voice analysis unit 801 brings the start of the voice frame interval forward and puts the end of the voice frame interval off so as to severally give margins for identifying voice and non-voice frames.
The voice analysis unit 801 identifies whether the frame that has been taken in is a voice frame or a non-voice frame in order from the analysis of the voice characteristic. The voice characteristic is data that identifies a voice frame and a non-voice frame of the code 300 . Specifically, the voice characteristic is formed by a number of zero-crossings and an amplitude level. The number of zero-crossings represents how many times a voice waveform of a zero-crossing wave crosses a zero level. The voice waveform of the zero-crossing wave is a waveform having no amplitude component. The amplitude level is an amplitude value of each of data 310 - 318 . The voice analysis unit 801 identifies, in a certain period of time, a frame of a data amplitude level being equal to or greater than a certain value and taken in a certain period of time since the number of zero-crossings becomes equal to or greater than a certain number until the number of zero-crossings becomes equal to or smaller than a certain number as a voice frame. In order to prevent portions of small amplitudes corresponding to a rise and a fall in voice from being clipped at a start and an end of a voice frame interval, respectively, the voice analysis unit 801 brings the start of the voice frame interval forward and puts the end of the voice frame interval off so as to severally give margins for identifying voice and non-voice frames.
The object frame selection unit 802 selects the non-voice frame detected by the voice analysis unit 801 as a frame to be replaced with the particular pattern 319 . Why the object frame selection unit 802 does not cause a voice frame to be a frame to be replaced with the particular pattern 319 is for preventing the particular pattern from causing noise. A non-voice frame is in general background noise data. Thus, a partial change of a non-voice frame can hardly be sensed as new voice quality degradation.
[Pattern Position Fixing Unit 805 ]
The particular pattern replacement unit 803 replaces a portion of the non-voice frame selected by the object frame selection unit 802 with the particular pattern 319 . The pattern position fixing unit 805 fixes a position of the non-voice frame to be replaced with the particular pattern. That is, the pattern position fixing unit 805 fixes particular pattern replacement positions of a plurality of non-voice frames in accordance with a given rule. The above given rule is, e.g., the amplitude levels at the particular pattern replacement positions are periodically different in a series of the non-voice frames to be replaced. That is, the particular pattern replacement positions of the respective non-voice frames have a periodic correlation.
A process by means of the pattern position fixing unit 805 for fixing particular pattern replacement positions in a plurality of non-voice frames will be explained here. The function processed by the pattern position fixing unit 805 is a new function that the pattern replacement unit 800 has in comparison with the pattern replacement unit 101 . The pattern position fixing unit 805 obtains a background noise level from the voice analysis unit 801 . Then, the voice analysis unit 801 performs an amplitude analysis of a frame identified as a non-voice frame, and determines the background noise level 320 . The amplitude analysis is a process by means of the voice analysis unit 801 for averaging amplitude values of non-voice frames for a certain period of time so as to cause the average value to be the background noise level. The pattern position fixing unit 805 causes a code pattern in a level range equal to or lower than the background noise level to be replaced with the particular pattern. The code pattern is a combination of bits of respective samples illustrating a same amplitude level in a frame formed by a plurality of samples. A portion of the code pattern to be replaced is formed by a combination of the codes in a level range equal to or lower than the background noise level, and the one formed with respect to the amplitude level is an example. If, e.g., the code 300 illustrated in FIG. 3 is taken as an example, the pattern position fixing unit 805 fixes a replacement position of the particular pattern 319 “010110 . . . 011”. The replacement position of the particular pattern 319 of the embodiment is a code pattern position of a level in the level range equal to or lower than the background noise level and closest to an average value of the level range.
Then, for a plurality of non-voice frames that the particular pattern replacement unit 803 obtains in chronological order, the pattern position fixing unit 805 fixes a position to be replaced with the particular pattern (particular pattern replacement position) in accordance with a certain rule. That is, the pattern position fixing unit 805 fixes the particular pattern replacement position of a non-voice frame while referring to the particular pattern replacement position of a past non-voice frame.
The particular pattern is saved in the detection use pattern saving unit 804 . The particular pattern replacement unit 803 reads the particular pattern from the detection use pattern saving unit 804 . Then, the particular pattern replacement unit 803 replaces the position of the code pattern fixed by the pattern position fixing unit 805 with the particular pattern. Further, the particular pattern replacement unit 803 does not perform a particular pattern replacement process for a silent frame of volume imperceptible for a person. The silent frame is a frame such that frame data includes all zero bits or at most bits indicating a faint sound of a value equal to or lower than a certain threshold.
[Configuration of Pattern Test Unit 900 ]
FIG. 9 illustrates a block diagram of a pattern test unit 900 of the embodiment.
The pattern test unit 900 can detect a level of inserted noise. The pattern test unit 900 detects the particular pattern replaced by the pattern replacement unit 800 . Then, the pattern test unit 900 can calculate amplitude data of a level of the inserted noise from detection positions of respective particular patterns in the non-voice frames which are tested in order.
The pattern test unit 900 is constituted by a voice analysis unit 901 , an object frame selection unit 902 , a pattern detection unit 903 and a detection use pattern saving unit 904 . The pattern detection unit 903 has a level estimation unit 905 . The level estimation unit 905 estimates amplitude data of noise inserted in the network from data with respect to whether or not particular patterns exist in a plurality of non-voice frames obtained in chronological order.
The voice analysis unit 901 takes in the code 300 every frame of 20 msec including 160 samples. Then, the voice analysis unit 901 identifies whether the frame that has been taken in is a voice frame or a non-voice frame in order.
The object frame selection unit 902 selects the non-voice frame identified by the voice analysis unit 901 as a detection object of the particular pattern.
The voice analysis unit 901 analyzes an amplitude value of the non-voice frame and determines a background noise level.
The pattern detection unit 903 obtains the background noise level from the voice analysis unit 901 , and determines a level range in which the particular pattern of the non-voice frame is tested with reference to the background noise level. Further, the particular pattern to be detected by the pattern detection unit 903 is saved in the detection use pattern saving unit 904 .
Thus, the pattern detection unit 903 reads the particular pattern saved in the detection use pattern saving unit 904 , and identifies whether or not the particular pattern exists in the non-voice frame while referring to the background noise level and the particular pattern that has been read.
[Level Estimation Unit 905 ]
Then, the level estimation unit 905 identifies regularity of the particular pattern detection positions of the non-voice frames obtained in order, and estimates amplitude data of noise inserted in the network. As to the pattern position fixing unit 805 of the pattern replacement unit 800 , the particular pattern replacement unit 803 fixes a position to be replaced with the particular pattern for a series of non-voice frames in accordance with a given rule. Thus, the level estimation unit 905 identifies whether or not detection positions of the particular pattern in a plurality of the non-voice frames obtained in chronological order follow the given rule. Moreover, upon identifying the particular pattern detection position as not following the given rule, the level estimation unit 905 estimates amplitude data of inserted noise from the particular pattern detection position that does not follow the given rule.
For a series of non-voice frames, e.g., the pattern position fixing unit 805 fixes particular pattern replacement positions at which the amplitude levels are periodically different. Upon identifying the amplitude levels of the particular pattern replacement positions in a series of non-voice frames as not following the given rule, the level estimation unit 905 estimates amplitude data of the inserted noise from to what extent periodicity of the amplitude level is disturbed, i.e., an average value of an amplitude level of a particular pattern that should have been detected (an amplitude level of a particular pattern that the pattern detection unit 903 has not detected owing to noise).
Upon identifying a particular pattern as existing in a non-voice frame, the pattern detection unit 903 sends pattern replacement existence data indicating that the particular pattern exists in the object non-voice frame to the detection identification unit. If the pattern detection unit 903 identifies a particular pattern as not existing in the non-voice frame, the pattern detection unit 903 sends pattern replacement absence data indicating that no particular pattern exists in the object non-voice frame to the detection identification unit. Further, the pattern detection unit 903 also sends amplitude estimation data of inserted noise calculated by the level estimation unit 905 to the detection identification unit. If there is no inserted noise, the amplitude data of the inserted noise indicates “nothing”, e.g., “0”.
FIG. 10 illustrates a flowchart of a process performed by the pattern test unit 900 of the embodiment.
The voice analysis unit 901 takes in the code 300 every frame of 20 msec including 160 samples, and cuts a frame out (step S 1001 ). The voice analysis unit 901 analyzes a voice characteristic of the frame that has been taken in (step S 1002 ).
The voice analysis unit 901 identifies whether the frame that has been taken in is a voice frame or a non-voice frame in order from the analysis of the voice characteristic (step S 1003 ).
If the voice analysis unit 901 identifies the frame that has been taken in as a non-voice frame (step S 1003 YES), the object frame selection unit 902 selects the non-voice frame as an object to be tested with respect to the particular pattern. Then, the pattern test unit 903 obtains the background noise level from the voice analysis unit 901 , and determines with reference to the background noise level a level range in which the particular pattern of the non-voice frame is tested (step S 1004 ). The level range in which the particular pattern is tested is a portion of the code pattern in the non-voice frame for which the level is determined with reference to the background noise level in accordance with a certain rule. The code pattern is data of a combination of codes in the level range equal to or lower than the background noise level. A voice code chain is, e.g., data formed by bits of respective samples illustrating a same amplitude level in a frame formed by a plurality of samples.
The particular pattern to be detected by the pattern detection unit 903 is saved in the detection use pattern saving unit 904 . The pattern detection unit 903 reads the particular pattern from the detection use pattern saving unit 904 , and identifies whether or not the particular pattern exists in the level range equal to or lower than the background noise level in the non-voice frame while referring to the particular pattern (step S 1005 ).
Upon identifying the particular pattern as existing in the non-voice frame (S 1005 YES), the pattern detection unit 903 sends pattern replacement existence data indicating that the particular pattern exists in the non-voice frame to the detection identification unit.
Upon identifying the particular pattern as not existing in the non-voice frame (step S 1005 NO), the level estimation unit 905 calculates amplitude data (noise level) of inserted noise (step S 1006 ). The level estimation unit 905 identifies regularity of particular pattern detection positions of non-voice frames obtained in order, and estimates the amplitude data of the noise (noise level) inserted in the network system. In other words, the level estimation unit 905 identifies whether or not detection positions of the particular pattern in a series of the non-voice frames follow the given rule. Upon identifying the particular pattern detection positions as not following the given rule, the level estimation unit 905 estimates amplitude data of inserted noise (noise level) from the particular pattern detection position that does not follow the given rule. The pattern detection unit 903 sends pattern replacement absence data indicating that no particular pattern exists in a non-silent frame and the amplitude data of the inserted noise to the detection identification unit.
Further, if the voice analysis unit 901 identifies the frame that has been taken in as a voice frame (step S 1003 NO), the pattern test unit 900 does not test the particular pattern 319 .
As the pattern replacement unit 800 performs a replacement process of a particular pattern on a non-voice frame that flows in the network system and the pattern test unit 900 performs a detection process of the particular pattern, noise inserted in the network system can thereby be detected and further an amplitude level of the noise can be identified.
The network system of the embodiment can detect voice quality degradation caused by noise inserted in, the quality controlled area 115 in the network. Further, the network system of the embodiment can also detect voice quality degradation caused by a transcoding for converting a compression format of data in the quality controlled area 115 in the network. According to the test method of the embodiment, further, the pattern replacement unit 800 replaces a portion of the non-voice frame with the particular pattern. Thus, an amount of data that flows through the network system 100 does not increase. Hence, according to the test method of the embodiment, a traffic increase in the network caused by the test of voice quality degradation can be avoided. That is, the test method of the embodiment enables the voice quality degradation to be tested without causing ill effects such as a traffic increase in the network and resultant congestion.
Further, the test system is constituted by including the pattern replacement unit 101 , the pattern test units 102 and 103 and the detection identification unit 104 . The test system may be constituted by including the pattern replacement unit 800 instead of the pattern replacement unit 101 , and the pattern test unit 900 instead of the pattern test units 102 and 103 . Further, the digital signal corresponds to a signal into which an analog voice signal is encoded. Further, the particular signal corresponds to a code that constitutes the particular pattern.
INDUSTRIAL APPLICABILITY
The test method of the present invention is for testing voice quality degradation in a packet switching network. Thus, the test method of the present invention is quite useful for implementing detection of a factor of voice quality degradation inserted in the network without affecting voice communication even while the network is being operated.
All examples and conditional language recited herein are intended for pedagogical purposes to aid the reader in understanding the invention and the concepts contributed by the inventor to furthering the art, and are to be construed as being without limitation to such specifically recited examples and condition, nor does the organization of such examples in the specification relate to a showing of superiority and inferiority of the invention. Although the embodiment of the present inventions have been described in detail, it should be understood that the various changes, substitutions, and alternations could be made hereto without departing from the spirit and scope of the invention. | A system for assessing a voice communication quality of a communication path between first and second nodes over a network, wherein coded data of voice communication signals are transferred in a stream of packets via the communication path, including: a capturing unit for capturing at the first node at least one packet containing coded data representing non voice signals among the packets of the coded data to be transferred from the first node to the second node; a replacing unit for replacing a part of the coded data representing non voice signals in the captured packet with a predetermined code before the captured packet is transferred from the first node; a retrieval unit for retrieving at the second node said at least one packet containing coded data representing non voice signals; and an assessment unit for assessing the voice communication quality of the communication path. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a device for actuating a lock on a vehicle door, wherein the term vehicle door includes any type of lid, hatch, flap, hood and the like on a vehicle. The device comprises: a support to be stationarily mounted on the door; a mount mountable on the support and configured either as a lock cylinder mount or as a lock cylinder-free mount (decoy); a shoulder on the mount that engages at least partially in the secured mounting position of the mount a counter shoulder provided on the support; a screw for securing the mounting position of the mount on the support; and an actuating end on the screw for a screwing adjustment of two end positions, i.e., a release position in which the mount can be mounted on or demounted from the support and a locking position in which the mount is secured in its mounting position on the support. In this configuration, the support to be mounted on the door not only supports the handle but also receives a lock cylinder mount or a lock cylinder decoy. The handle upon actuation acts on a lock in the door or the flap etc.; this holds true also for a lock cylinder when it is actuated by a matching key. These two alternatives, i.e., the lock cylinder mount and the lock cylinder decoy, will be referred to in the following simply as “mount”.
[0003] 2. Description of the Related Art
[0004] The devices of this kind are designed to enable, on the one hand, an easy and reliable mounting of the mount within the receptacle of the support and, on the other hand, to secure the mount after having been mounted properly on the support in a reliable way. For this purpose, the mount of the device has a shoulder that, at least in the secured mounting position of the mount, engages at least partially a counter shoulder provided on the support. For securing the mounting position in the mount, a screw is used whose actuating end is accessible from the narrow side of the door.
[0005] In a known device of the aforementioned kind, disclosed in German patent DE 30 30 519 C, the screw is a component of the support. The support has a threaded receptacle in which the screw is received. The inner end of the screw serves for securing the mount. Before mounting, the support is already stationarily secured on the inner side of the door and the mount is inserted from the exterior through an opening provided in the outer door panel of the door and is then mounted on the support by a mounting movement. During this mounting process, the screw is unscrewed out of the threaded receptacle to such an extent that the mounting movement for mounting the mount can be carried out; this mounting movement is comprised of an insertion phase and a subsequent displacement phase that is parallel to the insertion position. During this displacement phase of the mounting movement, the shoulder of the mount moves into a position behind the aforementioned counter shoulder on the support. This engaged position of the shoulder and counter shoulder is secured by the screw in that the screw is threaded into the threaded receptacle to such an extent that its inner end is supported on the sidewall of the mount. In this way, a movement reversing the mounting movement for demounting the mount is blocked. The movement of the mount in a reverse movement relative to the mounting movement is prevented by the tightened screw.
[0006] There are also devices where the securing action for the mounted mount on the support is not a direct action but is achieved indirectly, as disclosed in German patent application DE 199 50 172 A1. In this case, a slide is slidably received in guides of the support so as to be slidable in parallel. The slide has a threaded receptacle for a screw that is rotatably supported with its actuating end in an axially fixed position within the support. Before beginning the mounting process of the mount, the screw with its threaded inner end is screwed as far as possible into the threaded receptacle of the slide so that the slide is initially in a position remote from the mount. Then, the mount is inserted from the exterior side of the door into the support provided on the inner side of the door. When the screw is turned such that its threaded inner end is moved out of the threaded receptacle of the slide, the slide, because of the axially fixed rotational support of the screw, is moved more and more against the mount and the mount is parallel displaced within the support. This movement of the slide causes not only the mount to be displaced; moreover, the shoulders on the mount are moved behind the counter shoulders of the support and noses provided on the slide are moved into notches provided on the mount. The securing action is realized by the slide moved against the mount.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide a reliable and space-saving device of the aforementioned kind that can be handled comfortably and quickly for mounting and demounting of the mount and that ensures a reliable securing action of the mounted position of the mount on the support.
[0008] In accordance with the present invention, this is achieved in that the mount has a threaded receptacle for the screw and the screw is a component of the mount, in that the actuating end of the screw has correlated therewith a stationary support surface on the support, and in that, in the securing position, the actuating end of the screw is supported on the support surface of the support and secures the mounted position of the mount on the support.
[0009] The special feature of the invention resides in that the threaded receptacle of the screw provided for securing the mount is not located within the support or in a slide mounted on the support but is provided within the mount itself. According to the invention, the mount and the screw for securing the mount form of pre-assembled module. The support itself only must provide a stationary screw support surface on which, in the locking position, the actuating end of the screw is supported. During mounting, the screw is screwed into the mount as far as possible until the shoulder on the mount engages behind the counter shoulder provided on the support. Subsequently, for securing this mounting position of the mount on the support, the screw is unscrewed from the mount to such an extent that, as mentioned above, its actuating end rests against the screw support surface on the support. Not the inner end of the screw, as in the aforementioned prior art devices, but the opposed actuating end of the screw secures the engagement of the mount shoulder at the counter shoulder on the support.
BRIEF DESCRIPTION OF THE DRAWING
[0010] In the drawing:
[0011] FIG. 1 shows a side view of a first embodiment of the mount of the device according to the invention before being mounted on the support, wherein the mount does not have a lock cylinder to be actuated by a key and is only a mount decoy without lock cylinder;
[0012] FIG. 2 shows the bottom side of the mount illustrated in FIG. 1 ;
[0013] FIG. 3 is a support on which the mount according to FIG. 1 and FIG. 2 is mounted but not yet secured by the screw;
[0014] FIG. 4 shows, in a view analog to FIG. 2 , a second embodiment of the mount of the device according to the invention;
[0015] FIG. 5 shows in a view analog to the illustration of FIG. 1 a side view of the mount of FIG. 4 ;
[0016] FIG. 6 is a longitudinal section of the mount of FIG. 4 along section line VI-VI;
[0017] FIG. 7 shows a stabilization member of the mount illustrated in FIGS. 4 through 6 in a plan view;
[0018] FIG. 8 is an end view of the stabilization member of FIG. 7 in the direction of arrow VIII;
[0019] FIG. 9 is a side view of the stabilization member illustrated in FIGS. 7 and 8 in the direction of arrow IX of FIG. 7 ;
[0020] FIG. 10 shows a screw used in both embodiments for securing the mounted position of the mount on the support;
[0021] FIG. 11 shows in a view analog to FIG. 3 the yet unsecured position of the mount on the support where the screw is still in the release position so that the mount can still be inserted into and removed from the support; and
[0022] FIG. 12 shows in an illustration corresponding to FIG. 11 the securing position where the screw has been turned within the mount to such an extent by a screwing tool (not illustrated) that its actuating end is supported on the support surface provided on the support.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Only one end of the support 10 of the device is shown in FIG. 3 and FIGS. 11, 12 , respectively, for both embodiments. In both embodiments, the supports 10 are identical; the backside 11 of the support 10 mounted on the inner side of a door, not shown, is illustrated in the drawings. The fastening locations 13 for fastening means for fastening the door and the support 10 to one another are illustrated. The handle 15 for actuating a lock provided on the door is illustrated in dash-dotted lines only in FIG. 5 . The handle 15 is provided at the front side of the support 10 and is not illustrated in more detail; it is accessible from the exterior of the door for manual actuation. The elements that upon actuation of the handle 15 act on the lock pass through a cutout 18 provided within the support 10 . These elements of the handle 15 are not illustrated in FIGS. 3, 11 , and 12 .
[0024] Such a handle 15 can also be mounted on the support 10 at a later time, i.e., after the support 10 has been mounted on the door, from the outer side of the door through openings in the outer door panel. In this connection, one end of the handle is coupled with a bearing provided on the support while the other end of the handle has the aforementioned elements that are to be positioned in the cutout 18 of the support 10 . he cutout 18 has a sufficiently large size so that in addition to the mounted elements of the handle a mount 20 can be mounted. It will suffice to explain the configuration and the function of the mount with the aid of the second embodiment of FIGS. 4 through 10 because this second embodiment differs from the embodiment of FIGS. 1 and 2 only in that the mount has a separate stabilization member 26 on the mount housing 21 ; this area is of a monolithic configuration in the first embodiment of the mount. The stabilization member 26 reinforces the mount.
[0025] As can be seen best in FIG. 6 , the mount (decoy) 20 , as already mentioned, is comprised of a stabilization member 26 that is produced separately and receives the screw 30 illustrated in FIG. 10 and is inserted into a bore of the separately produced mount housing 21 . The mount 20 has a threaded receptacle 25 for the screw 30 illustrated in FIG. 10 . While in the first embodiment of FIGS. 1 and 2 this threaded receptacle is a component of the mount housing 21 , in the second embodiment, illustrated in FIGS. 7 through 9 , it is arranged in a bushing 28 of the stabilization member 26 .
[0026] The stabilization member 26 has the following configuration. At the outer end of the bushing 28 an end member 35 that is all around widened like a flange is provided that, upon insertion of the stabilization member 26 into a bore 43 of the mount housing 21 for forming a preassembled unit, will abut by means of an inner profile 29 according to FIG. 9 a counter profile 23 on the mount housing 21 . This bore 43 is illustrated in dashed lines in the section view of FIG. 6 . In the insertion position of the stabilization member 26 , the stabilization member 26 projects with projections 46 , illustrated in FIG. 7 , from the end member 35 on opposed sides of the mount housing 21 . This is also illustrated in FIG. 4 . Slanted surfaces 24 that can be seen particularly well in FIG. 7 are provided at this location; as will be explained in more detail in the following, these slanted surfaces 24 cooperate with slanted counter surfaces 34 of the support 10 in the securing position.
[0027] The module 21 , 26 , 30 of the second embodiment of FIG. 6 and the module 21 , 30 of the first embodiment according to FIG. 1 are mounted from the exterior side of the door through an opening in the outer door panel in the cutout 18 of the support 10 . This can be realized by an assembling movement 40 that has two movement phases illustrated by arrows 41 , 42 in FIG. 6 . In the first movement phase 41 , the mount is inserted substantially perpendicularly to the door plane; subsequently, a movement phase 42 moves the inserted mount 28 within the support 10 in a direction perpendicular to the first movement phase 41 . During this assembling movement 40 , the shoulders 22 provided on the mount 20 engage counter shoulders 12 on the support 10 ; the counter shoulders 12 are only schematically illustrated in FIGS. 3 and 11 . While the shoulders 22 are formed by a groove 27 in the mount housing 21 provided with inner surfaces, as illustrated in FIG. 6 , the counter shoulders 12 are in the form of ribs 17 formed on the support 10 . FIG. 3 and FIG. 11 , respectively, show the end position of the mount 20 after completion of mounting within the support 10 . The head 36 of the housing illustrated in FIG. 5 and FIG. 6 is now positioned on the exterior side of the door in front of the door panel 38 illustrated in FIG. 5 in dashed lines. Adjacent to the housing head 36 of the mounted mount 20 , a portion of the lock of the handle 15 is positioned as illustrated in FIG. 5 in dashed lines. In FIG. 5 , the position of the support 10 is not shown.
[0028] Upon completion of assembly according to FIGS. 3 and 11 , the screw 30 is screwed into the threaded receptacle 25 in the mount housing 21 or in the stabilization member 26 to the maximum extent. This is indicated in FIG. 3 and FIG. 11 by the auxiliary line 30 . 1 ; this is referred to as the release position of the screw 30 . As shown in FIG. 10 , the screw 30 is provided with a flange 32 in the area of its actuation end 31 . The release position 30 . 1 can be secured in that the flange 32 is moved into a flange receptacle 39 in the widened end member 25 of the stabilization member 26 or the mount housing 21 and rest against the receptacle 39 .
[0029] In the mounted position of the mount 20 , the actuation end 31 of the screw 30 that is in the release position 30 . 1 is aligned with a cutout 37 provided within the support end 14 ( FIG. 3 ) and providing an access to the actuation end 31 . From the narrow side of the door where a hole is provided, a screwing tool can be inserted into the tool receptacle in the actuation end 31 of the screw 30 . By means of the screwing tool, the screw 30 is then moved out of the mount 20 in the direction toward the support end 14 . On the support 10 , a stationary screw support surface 16 is provided that faces the screw 30 . The movement of the screw 30 in the outward direction will end when the screw 30 abuts the screw support surface 16 as shown in FIG. 12 . The unscrewed screw 30 is now in the locking position for securing the mount in the securing position; the locking position of the screw 30 is indicated by the auxiliary line 30 . 2 . In the present configuration, the stop function is realized in that the actuation end 31 itself will come to rest against the screw support surface 16 . The afore described flange 32 rests annularly against the surface 16 . This flange 32 is provided with a lock toothing 33 illustrated in FIG. 10 that digs or penetrates into the support surface 16 of the support 10 in the locking position 30 . 2 shown in FIG. 12 . Since the lock toothing 33 has a sawtooth profile, the return movement of the screw 30 out of its securing position 30 . 2 is made significantly more difficult. In this way, a particularly reliable locking of the mount 20 in its mounting position in the support 10 is provided.
[0030] According to the prior art, a worker who must mount such devices on doors or flaps of vehicles, is used to rotate the tool in the clockwise direction in order to transfer the screw for securing the mounted mount 20 in the securing position. However, according to the invention, the screw, as described above, is moved out of the mount 20 with its actuating end 31 during this securing action. In the case of a conventional right-handed thread of the prior art, the screw 30 therefore would have to be rotated in the counter-clockwise direction. The worker therefore would be required to retrain mounting of the device according to the invention and rotate the screwing tool in the opposite direction. This would be confusing to a worker when, at times, he would have to mount also prior art devices in between. For this reason, it is proposed to provide the screw 30 and the threaded receptacle within the mount as so-called left-handed threads. In this case, the worker can actuate the screwing tool in the clockwise direction as usual because the screw will then be axially moved out of the mount 20 . This has the advantage that the worker must not pay attention whether the device to be mounted is configured according to the invention or according to the prior art.
[0031] When the mount 20 is mounted, the slanted surface 24 shown in FIGS. 7 and 9 of the end member 35 of the stabilization member 26 and the slanted counter surface 34 of the support 10 cooperate. In the securing position 30 . 2 , there is not only the tightening action of the stabilization member 26 on the counter surface and of the flange 32 of the actuating end 31 on the support surface 16 but, in addition, a tightening or pulling action will result that is illustrated in FIG. 5 by arrow 19 . In FIG. 5 , the position of the slanted counter surface 34 is indicated in dashed lines. Upon tightening, the slanted surface 24 moves against the stationary slanted counter surface 34 of the support 10 and generates a torque causing the aforementioned pulling action 19 that pulls the mount 20 toward the support 10 and against the outer door panel 38 that is illustrated in FIG. 5 in dash-dotted lines. The screw axis 44 of the screw 30 , illustrated in FIG. 5 by a dashed line, has an angled position 45 relative to the support 10 that extends in this area substantially parallel to the outer door panel 38 (illustrated in FIG. 5 in dash-dotted lines).
[0032] While specific embodiments of the invention have been shown and described in detail to illustrate the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles. | A device for actuating a lock on a vehicle door has a support mounted on a vehicle door. A lock cylinder mount, or a decoy, is mounted on the support. A screw secures the mount when mounted on the support. The mount has a shoulder engaging a counter shoulder of the support at least partially in the mounting position of the mount. The screw has an actuating end for moving the screw into a release position and a locking position. In the release position, the mount is removable from and mountable on the support. In the locking position, the mount is secured. The mount has a threaded receptacle for the screw so that the screw is part of the mount. The support has a screw support surface against which the actuating end of the screw rests in the locking position of the screw for securing the mount. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a novel liquid crystal substance and a liquid crystal composition containing the same, and more particularly it relates to a chiral liquid crystal substance having an optically active group and a chiral liquid crystal composition containing the same.
2. Description of the Prior Art
Among liquid crystal display elements, those of twisted nematic (TN) type display mode have currently been most widely used, but they are inferior in response rate to emissive type display elements (e.g. electroluminescence, plasma display, etc.), and various improvements in this respect have been attempted, but it appears, nevertheless, that possibility of notable improvement has not been left behind so much. Thus, various liquid crystal display devices based on a different principle from that of TN type display elements have been tried in place thereof. Among these devices, there is a device of display mode utilizing ferroelectric liquid crystals (N. A. Clark et al, Applied Phys. lett., 36, 899 (1980)). This mode utilizes the chiral smectic C phase (hereinafter abbreviated to S C * phase), the chiral smectic H phase (hereinafter abbreviated to S H * phase) or the like of ferroelectric liquid crystals, and substances having such phases in the vicinity of room temperature have been desired as those suitable to this mode.
The present inventors have previously found some chiral smectic liquid crystal compounds suitable to such object and applied for patent (e.g. Japanese patent application Nos. Sho 58-640/1983, Sho 58-78594/1983, Sho 58-119,590/1983, etc.).
The present inventors have further made extensive research on liquid crystal substances having an optically active group in order to find superior compounds suitable to the above display mode, and as a result have found compounds of the present invention.
SUMMARY OF THE INVENTION
The present invention resides in a compound expressed by the formula ##STR4## wherein R represents an alkyl group of 1 to 18 carbon atoms; R* represents an optically active alkyl group of 4 to 15 carbon atoms; X represents single bond, --O--, ##STR5## Y represents --CH 2 O-- or --OCH 2 --; Z represents single bond, --O--, ##STR6## and m and n each represent 1 or 2, and a liquid crystal composition containing the same.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Spontaneous polarization values (Ps) of display elements constituted by the use of the chiral smectic compounds and compositions of the present invention are compared with those of liquid crystal compounds having ##STR7## in place of --CH 2 O-- or --OCH 2 -- as Y in the formula (I) expressing the compound of the present invention, recited in Japanese patent applications of the present inventors previously filed (Sho 58-78,594 (1983), Sho 59-119,590 (1984) and Sho 59-142,699 (1984)). As a result, the Ps values of the compounds of the present invention are greater than those of the latter compounds and those of some of the compounds are twice or greater.
Greater Ps values result in various advantages such as lower voltage drive, higher rate responce properties, etc. when display elements are prepared from the compounds. Table 1 shows comparison of Ps values of representatives of the compounds of the present invention expressed by the formula (I), with those of compounds corresponding thereto recited in the patent applications of the present inventors previously filed.
In addition, the Ps values were obtained by measurement at temperatures lower by 10° C. than the upper limit of temperature range exhibiting S C * phase.
TABLE 1__________________________________________________________________________Structural formula Ps (nC/cm.sup.2) Sample No.__________________________________________________________________________Compounds of formula (I) ##STR8## 47 14 ##STR9## 80 9 ##STR10## 105 23Compounds of applicationspreviously filed ##STR11## 38 ##STR12## 47 ##STR13## 43__________________________________________________________________________
In the case of constituting chiral smectic liquid crystal compositions, it is possible to constitute them from a plurality of the compounds of the formula (I), alone, and it is as possible to blend the compound(s) of the formula (I) with other smectic liquid crystals to thereby prepare a liquid crystal composition exhibiting S C * phase. Display elements exhibiting the light-switching effect of S C * phase have the following three superior specific features as compared with those of TN display mode:
The first specific feature is that the display elements reply at a very high rate so that the response time is 1/100 or less of those of conventional TN mode display elements. The second specific feature is that there is a memory effect so that the multiplex drive is easy in combination thereof with the above high rate response properties. The third specific feature is that when the gray scale is given in the case of TN display mode, this is effected by adjusting the impressed voltage, but there are raised difficult problems such as temperature dependency of threshold voltage, temperature dependency of response rate, etc.; whereas when the light-switching effect of S C * phase is applied, it is possible to readily obtain the gray scale by adjusting the reverse time of polarility and hence the display elements are very suitable to graphic display.
As to the display method, the following two may be considered:
One method is of birefringence type using two plates of polarizers and another is of guest-host type using a dichlroic dyestuff. Since S C * phase has a spontaneous polarization, the molecule is reversed around the helical axis as a rotating axis by reversing the polarity of impressed voltage. When a liquid crystal composition having S C * phase is filled in a liquid crystal display cell subjected to aligning treatment so that the liquid crystal molecules can be aligned in parallel to the electrode surface, followed by placing the liquid crystal cell between two plates of polarizers arranged so that the director of the liquid crystal molecules can be in parallel to the polarization plane on one side, impressing a voltage and reversing the polarity, then a bright field of view and a dark field of view are obtained depending on the opposition angle of the polarizers. On the other hand, in the case of operation by way of the guest-host type, it is possible to obtain a bright field of view and a colored field of view (depending on the arrangement of the polarization plate), by reversing the polarity of impressed voltage.
In addition, compounds of racemic form corresponding to those of the formula (I) are prepared in a similar manner to that in the case of the latter compounds, that is, by using as raw material, compounds of racemic form in place of optically active compounds in the preparation of optically active compounds (I) described below, and the former compounds of racemic form exhibit almost the same phase transition points as those of the latter compounds (I). The compounds of racemic form exhibit S C phase in place of S C * phase, and when they are added to the optically active compounds of formula (I), it is possible to adjust the helical pitch of chiral smectic phases.
Since the compounds of the formula (I) also have an optically active carbon atom, they have a capability of inducing a twisted structure when added to nematic liquid crystals. Nematic liquid crystals having a twisted structure i.e. chiral nematic liquid crystals do not form the so-called reverse domain of TN type display elements; hence it is possible to use the crystals as an inhibitor against reverse domain formation.
Table 2 shows the phase transition points of representatives of the compounds of the formula (I) of the present invention.
TABLE 2__________________________________________________________________________Sam-ple In formula (I) Phase transition point Re-egree.C.)No. R X m Yn Z R** C S.sub.2 S.sub.1 S.sub.C * S.sub.A I__________________________________________________________________________ mark 1 C.sub.6 H.sub.13 single 1CH.sub.2 O2 single 2- · 126.5 -- (S.sub.B · 124.5) -- --· bond bond MeBu 2 C.sub.7 H.sub.15 single 2OCH.sub.21 O 1- · 78.1 -- -- · 101.7 --· Ex. bond MeHep 2 3 C.sub.8 H.sub.17 single 1OCH.sub.22 single 2- · 72.5 S.sub.H * · 95.3 S.sub.F * · · 100.7 · 106.0· bond bond MeBu 4 C.sub.9 H.sub.19 single 1OCH.sub.22 single 2- · 69.5 -- S.sub.F * · · 100.8 · 107.0· bond bond MeBu 5 C.sub.7 H.sub.15 O 1CH.sub.2 O1 O 2- · 57.6 -- (S.sub.B · 42.1) (· 46.2) --· MeBu 6 C.sub.7 H.sub.15 O 1CH.sub.2 O1 O 1- · 28.5 -- -- -- MeHep 7 C.sub.5 H.sub.11 O 1CH.sub.2 O2 O 1- · 129.5 · 146.1 · 157.6 · 164.6 --· MeHep 8 C.sub.7 H.sub.15 O 1CH.sub.2 O2 O 2- · 119 · 127 · 153.0 · 161.6 --· MeBu 9 C.sub.7 H.sub.15 O 1CH.sub.2 O2 O 1- · 80.1 -- -- · 117.9 --· Ex. MeHep 310 C.sub.11 H.sub.23 O 1CH.sub.2 O2 O 1- · 90.7 · 100 -- · 114.0 --· MeHep11 C.sub.14 H.sub.29 O 1CH.sub.2 O2 O 1- · 93.3 · 96.8 -- · 109.7 --· MeHep12 C.sub.8 H.sub.17 O 2CH.sub.2 O1 single 2- · 98.4 -- · 110.6 · 136.7 · 137.4· bond MeBu13 C.sub.8 H.sub.17 O 2CH.sub.2 O1 O 2- · 95 · 107.4 -- · 135.0 · 155.0· MeBu14 C.sub.8 H.sub.17 O 2CH.sub.2 O1 O 1- · 63.4 -- -- · 116.0 --· Ex. MeHep 115 C.sub.8 H.sub.17 O 2CH.sub.2 O1 O 4- · 53.5 S.sub.H * · 91.0 S.sub.G * · 135.2 · 157.5 --· MeHex16 C.sub.8 H.sub.17 O ##STR14## 3- MePe · 113.5 -- -- · 147.9 · 158.1·17 C.sub.8 H.sub.17 O ##STR15## 3- MePe · 52.5 -- S.sub.G * · 137.8 · 162.5 --·18 C.sub.10 H.sub.21 O 1OCH.sub.21 single 2- · 44.2 -- -- -- --· bond MeBu19 C.sub.12 H.sub.25 O 1OCH.sub.21 single 2- · 50.2 -- -- -- --· bond MeBu20 C.sub.8 H.sub.17 O 1OCH.sub.21 O 1- · 38 -- -- -- --· MeHep21 C.sub.12 H.sub.25 O 1OCH.sub.21 O 2- · 54 -- -- -- --· MeBu22 C.sub.8 H.sub.17 O 2OCH.sub.21 O 2- · 93 · 140.8 -- · 168.3 --· MeBu23 C.sub.9 H.sub.19 O 2OCH.sub.21 O 1- · 88.3 · 113.0 -- · 128.2 --· MeHep24 C.sub.10 H.sub.21 O 2OCH.sub.21 single 2- · 85 S.sub.E * · 139.1 S.sub.H * · 142.3 · 143.5 --· bond MeBu25 C.sub.8 H.sub.17 O 1OCH.sub.22 O 1- · 109.0 -- -- · 112.0 --· MeHep26 C.sub.4 H.sub.9 O 1OCH.sub.22 single 2- · 129.3 -- -- (· 119.5) (· 128.3)· bond MeBu27 C.sub.6 H.sub.13 O 1OCH.sub.22 single 2- · 112.0 (S.sub.H * · 107.1) (S.sub.F * · · 122.9 · 126.3· bond MeBu28 C.sub.8 H.sub.17 O 1OCH.sub.22 single 2- · 106.5 (S.sub.H * · 98.0) S.sub.F * · 107.9 · 123.4 · 125.0· bond MeBu29 C.sub.10 H.sub.21 O 1OCH.sub.22 single 2- · 102.5 (S.sub.H * · 98.0) S.sub.F * · 105.5 · 120.7 · 122.4· bond MeBu30 C.sub.12 H.sub.25 O 1OCH.sub.22 single 2- · 86.0 -- S.sub.F * · 104.3 · 117.9 · 120.5· bond MeBu31 C.sub.8 H.sub.17 ##STR16## 1OCH.sub.22 O 1- MeHep · 105.7 -- -- -- · 125.3·32 C.sub.7 H.sub.15 ##STR17## 1OCH.sub.22 single bond 2- MeBu · 77.0 -- -- -- · 86.7·33 C.sub.8 H.sub.17 O ##STR18## 2- MeBu · 56.7 -- S.sub.I * · 133.6 · 152.9 · 153.4·__________________________________________________________________________ *: Me represents methyl; Bu, butyl; Hep, heptyl; Hex, hexyl; and Pe, pentyl
In the column of "phase transition point" in Table 2, the symbols "." below the symbols representing the respective phases (C, S 2 , S 1 , S C *, S A , I) show that the respective phases are present there, and the symbols "-" show that the respective phases are absent there. Further, a numeral figure on the right side of a sumbol "." represents the phase transition point from a phase at the symbol "." to a phase at a symbol "." on the right side of the numeral figure. Further, the symbols "( )" each show monotropic liquid crystal.
Next, preparation of the compounds of the formula (I) will be described.
First, preparation of compounds of formula (Ia) i.e. compounds of formula (I) wherein Y represents --CH 2 O-- will be described. ##STR19##
The compounds of formula (I a ) may be prepared for example as shown in the following figure: ##STR20##
In this figure, R, R*, X, Z, m and n each are as defined above. L represents a group to be eliminated such as halogen atom, tosyloxy group, methylsulfonyloxy group, etc.
Namely, a compound of (IIa) is reacted with a compound (IIIa) in the presence of an alkali in a solvent such as acetone, dimethylformamide (hereinafter abbreviated to DMF), dimethylsulfoxide (hereinafter abbreviated to DMSO), etc. to obtain a compound of (Ia).
As the compound of (IIa) as one of the raw materials, the following compounds having either one of the groups indicated as X in formula (I) and a value of 1 or 2 as m therein may be enumerated: ##STR21##
As the compound of (IIIa) as another of the raw materials, the following compounds having either one of the groups indicated as Z in formula (I) and a value of 1 or 2 as n therein may be enumerated: ##STR22##
Next, preparation of compounds of formula (Ib), i.e. compounds of formula (I) wherein Y represents --OCH 2 -- will be described. ##STR23##
The compounds of formula (Ib) may be prepared for examples as shown in the following figure: ##STR24##
In this figure, R, R*, X, Z, m and n each are as defined above. L represents a group to be eliminated such as halogen atom, tosyloxy group, methylsulfonyloxy group, etc.
Namely, a compound of formula (IIb) is reacted with a compound of formula (IIIb) in the presence of an alkali in a solvent such as acetone, DMF, DMSO, etc. to obtain a compound of formula (Ib).
As the compound (IIb) as one of the raw materials, the following compounds having either one of the groups indicated as X in formula (I) and a value of 1 or 2 as m therein may be enumerated: ##STR25##
As the compound of formula (IIIb) as another of the raw materials, the following compounds having either one of the groups indicated as Z in the formula (I) and a value of 1 or 2 as n therein may be enumerated: ##STR26##
The optically active liquid crystal compounds and liquid crystal compositions of the present invention will be described in more detail by way of Examples.
EXAMPLE 1
Preparation of optically active 4'-octyloxy-4-(p-(1-methylheptyloxy)phenyloxy)methyl-biphenyl (a compound of formula (I) wherein R represents C 8 H 17 ; R*, 1-methylheptyl; X, --O--; Y, --CH 2 O--; Z, --O--; m, 2; and n, 1) (No. 14 in Table 1)
(i) Preparation of 4'-octyloxy-4-chloromethyl-biphenyl
4'-Octyloxy-4-formyl-biphenyl (30 g) was suspended in isopropyl alcohol (100 ml), followed by pouring in the resulting suspension, a suspension of sodium boron hydride (1.22 g) in isopropyl alcohol (100 ml), stirring the mixture at 70° C. for 4 hours, adding 6H-HCl (20 ml) and water (10 ml), stirring the mixture at 70° C. for 2 hours, allowing to stand overnight, filtering and collecting the resulting crystals and recrystallizing from ethanol to obtain 4'-octyloxy-4-hydroxymethyl-biphenyl (28.5 g) having a m.p. of 141.6° C. This product (16 g) together with thionyl chloride (12 g) were heated for 6 hours, followed by distilling off excess thionyl chloride and recrystallizing the residue from tolueneheptane to obtain 4'-octyloxy-4-chloromethyl-biphenyl (IIa-8) (14.8 g) having a m.p. of 101° C.
(ii) Preparation of p-(1-methylheptyloxy)phenol
p-Benzyloxyphenol (50 g), ethanol (150 ml) and 50% NaOH aqueous solution (25 g) were mixed with stirring, followed by pouring in the mixture, optically active 1-methylheptyl p-toluenesulfonate derived from S-(+)-2-octanol, heating the mixture under reflux for 4 hours, distilling off most of ethanol, extracting with toluene, washing with acid, alkali and water, drying, concentrating and purifying the concentrate according to column chromatography with activated alumina (150 g) to obtain oily p-benzyloxy-(1-methylheptyloxy)benzene (68.6 g), which was then subjected to hydrogenolysis with 5% Pd-C catalyst in ethanol, followed by removing the catalyst, concentrating the solution and subjecting the concentrate to vacuum distillation to obtain oily p-(1-methylheptyloxy)phenol (IIIa-2) (30.7 g) having a b.p. of 129°-130.5° C./0.5 Torr.
(iii) Preparation of the captioned compound
Sodium hydride (0.37 g) was decanted first with heptane, then with THF and placed in a flask in nitrogen stream, followed by dropwise adding a solution of p-(1-methylheptyloxy)phenol (1.5 g) obtained in the above (ii) in THF (20 ml) so that the liquid temperature might not exceed 40° C., then dropwise adding DMSO (20 ml), successively dropwise adding a solution of 4'-octyloxy-4-chloromethyl-biphenyl (1.8 g) obtained in the above (i) in DMSO (40 ml), stirring the mixture at room temperature, allowing to stand overnight, adding 6N-HCl (100 ml), extracting with toluene, washing the toluene layer with acid, washing with alkali, washing with water to make it neutral, drying, concentrating, subjecting the residue to column chromatography with Al 2 O 3 (10 g), concentrating and twice recrystallizing the concentrate with a mixed solvent of ethanol (20 ml) and ethyl acetate (20 ml) to obtain the captioned 4'-octyloxy-4-(p-(1-methylheptyloxy)phenyloxy)methyl-biphenyl (1.8 g). Its phase transition points are described in Table 2 (No. 14). Further its elementary analysis values accorded well with its calculated values as follows:
______________________________________ Calculated value Observed value (in terms of C.sub.35 H.sub.48 O.sub.3)______________________________________C 81.1% 81.35%H 9.2% 9.36%______________________________________
EXAMPLE 2
Preparation of 4'-heptyl-4-(p-1-methylheptyloxy)phenyl)methyloxy-bisphenyl (a compound of formula (I) wherein R represents C 7 H 15 ; R*, 1-methylheptyl; X, single bond; Y, --OCH 2 --; Z, --O--; m, 2; and n, 1) (No. 2 in Table 1)
(i) Preparation of p-(1-methylheptyloxy)benzyl chloride
p-Hydroxy-benzaldehyde (15 g), ethanol (200 ml) and 50% NaOH (12 g) were mixed with stirring, followed by pouring in the mixture, a tosylate (26 g) derived from S-(+)-2-octanol, heating the resulting mixture under reflux for 6 hours, distilling off most of ethanol, adding 6N-HCl (100 ml), extracting with toluene, washing the toluene layer with acid, washing with alkali, washing with water to make it neutral, drying, concentrating, and further concentrating the resulting concentrate according to column chromatography with Al 2 O 3 (40 g) to obtain oily p-(1-methylheptyloxy)benzaldehyde (13.0 g). Next, sodium boron hydride (1.0 g) was suspended in isopropyl alcohol (50 ml), followed by dropwise adding to the suspension, a solution of p-(1-methylheptyloxy)benzaldehyde obtained above in isopropyl alcohol (100 ml) so that the liquid temperature might not exceed 40° C., stirring the mixture at 60° C. for 4 hours, adding 6N-HCl (30 ml) and water (20 ml), further heating with stirring at 60° C., distilling off the solvent, extracting the residue with toluene, washing the toluene layer with acid, washing with alkali, washing with water to make it neutral, drying and concentrating to obtain raw p-(1-methylheptyloxy)benzyl alcohol (13 g), which was then heated together with thionyl chloride for 6 hours, followed by distilling off excess thionyl chloride under reduced pressure to obtain raw p-(1-methylheptyloxy)benzyl chloride (IIIb-2) (13 g), which was used, as it was, in the following reaction.
(ii) Preparation of the captioned compound
Sodium hydride (0.21 g) was decanted with n-heptane (20 ml), successively with THF (20 ml) and placed in a flask in nitrogen stream, followed by dropwise adding a solution of 4'-heptyl-4-hydroxy-biphenyl (IIIa-6) (1.18 g) in THF (10 ml), adding DMSO (20 ml) to form a uniform solution. To this solution was dropwise added a solution of p-(1-methyloxy)benzyl chloride (1.05 g) obtained in the above (i) in DMSO (20 ml), followed by stirring the mixture at room temperature, allowing to stand overnight, adding 6N-HCl (100 ml), extracting with toluene, washing the toluene layer with acid, washing with alkali, washing with water to make it neutral, drying, concentrating, subjecting the residue to column chromatography with activated alumina (10 g) to effect separation-concentration using toluene as an elute, and twice recrystallizing from a mixed solvent of ethanol (20 ml) and ethyl acetate (20 ml) to obtain the captioned 4'-heptyl-4-(p-(1-methylheptyloxy)phenyl)methyloxy-biphenyl (0.6 g). Its phase transition points are described in Table 2 (No. 2).
Further its elementary analysis values accorded well with its calculated values as follows:
______________________________________ Calculated value Observed value (in terms of C.sub.34 H.sub.46 O.sub.2)______________________________________C 84.1% 83.90%H 9.3% 9.53%______________________________________
EXAMPLE 3
Preparation of 4'-(p-heptyloxy)phenylmethyloxy)-4-(1-methylheptyloxy)-biphenyl (a compound of formula (I) wherein R represents C 7 H 15 ; R*, 1-methylheptyl; X, --O--; Y, --CH 2 O--; m, 1 and; n, 2) (No. 9 in Table 1)
(i) Preparation of p-heptyloxybenzyl bromide
A suspension of sodium boron hydride (6.9 g) in isopropyl alcohol (500 ml) was dropwise added to a solution of p-heptyloxybenzaldehyde (119 g) in isopropyl alcohol (300 ml), followed by heating the mixture to 70° C. to form a uniform solution, which was then agitated at 70° C. for 3 hours and allowed to stand overnight, followed by adding 6N-HCl (100 ml) and water (200 ml), heating the mixture to 60° C., distilling off most of the solvent, extracting with toluene, washing with water, washing with alkali, washing with water to make it neutral, drying, concentrating and recrystallizing the residue from a mixed solvent of ethanol (200 ml) and water (60 ml) to obtain p-heptyloxybenzyl alcohol (74.9 g). This product (40 g) together with 47% aqueous hydrogen bromic acid (200 g) were agitated at 80° C. for 7 hours and allowed to stand overnight, followed by extracting with n-heptane (200 ml), washing the n-heptane layer with water till the washing water became neutral, drying, concentrating and subjecting the residue to vacuum distillation to obtain p-heptyloxybenzyl bromide (IIa-2) (28 g) having a b.p. of 174°-175° C./6 Torr.
(ii) Preparation of the captioned compound
Sodium hydride (0.8 g) was decanted twice with n-heptane (20 ml), successively with THF (20 ml) and placed in a flask in the form of a suspension in THF (20 ml), followed by dropwise adding a solution of 4'-hydroxy-4-(1-methylheptyloxy)-biphenyl (IIIa-7) of m.p. 98.1° C. (5.1 g) obtained by reacting 4,4'-dihydroxybiphenyl with a tosylate derived from S-(+)-2-octanol, in THF (30 ml), thereafter dropwise adding DMSO (20 ml), successively dropwise adding a solution of p-heptyloxybenzyl bromide (5.4 g) in DMSO (30 ml), stirring the mixture at room temperature, allowing to stand overnight, adding 6N-HCl (200 ml), extracting with toluene, washing with acid, washing with alkali, washing with water to make it neutral, drying, concentrating, subjecting the concentrate to column chromatography with activated alumina (20 g) to effect separation-concentration using toluene as an elute, and twice recrystallizing from a mixed solvent of ethanol (40 ml) and ethyl acetate (20 ml) to obtain the captioned 4'-(p-(heptyloxy)phenylmethyloxy)-4-(1-methylheptyloxy)biphenyl (3.6 g). Its m.p., etc. are described in Table 2. Further its elementary analysis values accorded well with its calculated values as follows:
______________________________________ Calculated values Observed value (in terms of C.sub.34 H.sub.45 O.sub.3)______________________________________C 81.4% 81.23%H 9.1% 9.22%______________________________________
EXAMPLE 4 (USE EXAMPLE 1)
A nematic liquid crystal composition consisting of
______________________________________4-ethyl-4'-cyanobiphenyl 20%,4-pentyl-4'-cyanobiphenyl 40%,4-octyloxy-4'-cyanobiphenyl 25%, and4-pentyl-4'-cyanoterphenyl 15%,______________________________________
was filled in a cell (distance between electrodes: 10 μm) composed of transparent electrodes subjected to parallel aligning treatment by applying polyvinyl alcohol (PVA) and rubbing the resulting surface to form a TN type display cell, which was observed by a polarizing microscope. As a result, formation of a reverse twist domain was observed.
To the above nematic liquid crystal composition was added a compound of formula (I) of the present invention wherein m represents 1; n, 2; R, C 6 H 13 ; X, single bond; Y, --CH 2 O--; Z, single bond; and R*, 2-methylbutyl (No. 1 in Table 2) in a quantity of 0.1% by weight, to observe the mixture in the same TN type cell as above. As a result the reverse twist domain was dissolved and a uniform nematic phase was observed.
EXAMPLE 5 (USE EXAMPLE 2)
A liquid crystal composition consisting of the following compounds of the present invention: ##STR27## exhibits S C * phase in a broad temperature range of from 45° C. to 98° C., exhibits S A phase at higher temperatures than the above, and forms an isotropic liquid at 107° C.
This blend exhibits a spontaneous polarization value as large as 12 nC/cm 2 at 50° C. and yet its tilt angle is 22°; hence it is optimum for birefringence type display elements using two polarizing plates.
This blend was filled in a cell of 2 μm thick equipped with transparent electrodes subjected to parallel aligning treatment by applying PVA and rubbing the surface. The resulting liquid crystal cell was placed between two plates of polarizers arranged in a crossed state, and an alternating current for a low frequency of 0.5 Hz and 15 V was impressed. As a result, a clear switching operation having a good contrast was observed, and yet the resulting liquid crystal display element had a response rate as fast as 0.8 m sec at 50° C.
EXAMPLE 6 (USE EXAMPLE 3)
A liquid crystal composition consisting of as compounds of the present invention, ##STR28## as known, ferroelectric compounds having a small spontaneous polarization value (about 1 nC/cm 2 ) and yet having a large tilt angle of 45°, ##STR29## exhibits S C * phase in a range of from 50° C. to 95° C., exhibits Ch phase at higher temperatures than the above and forms an isotropic liquid at 142° C.
This blend has a tilt angle as large as 42° at 55° C., and hence it is very suitable to the so-called guest-host type display elements using dichroic dyestuffs, and yet it exhibited as large a spontaneous polarization value as 44 nC/cm 2 .
To this blend was added an anthraquinone dyestuff (D-16, tradename of product made by BDH Company) in a quantity of 3% by weight to prepare a guest-host type liquid crystal composition, which was filled in the same cell as in Example 5 (but cell thickness: 10 μm), and one plate of polarizer was arranged so that its polarization plane might be in parallel to the axis of molecules and an alternate current of a low frequency of 0.5 Hz and 15 V was impressed. As a result, a clear switching operation was observed and there was obtained a color liquid crystal display element having a very good contrast and yet a response rate as very fast as 0.5 m sec at 55° C. | A novel chiral liquid crystal compound having an optically active group which affords a superior response rate when used as a liquid crystal display element, and a liquid crystal composition containing the same are provided, which chiral liquid crystal compound is expressed by the formula ##STR1## wherein R represents an alkyl group of 1 to 18 carbon atoms; R* represents an optically active alkyl group of 4 to 15 carbon atoms; X represents single bond, --O--, ##STR2## Y represents --CH 2 O-- or --OCH 2 --; Z represents single bond, --O--, ##STR3## and m and n each represent 1 or 2. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application is related to a pending U.S. patent application entitled “PLUG CONNECTOR HAVING A LATCHING MECHANISM”, which is invented by the same inventor as this patent application and assigned to the same assignee with this application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a cable end connector, and more particularly to a plug connector used for high-speed signal transmission.
2. Description of Related Art
A committee called SFF is an ad hoc group formed to address storage industry needs in a prompt manner. When formed in 1990, the original goals were limited to define de facto mechanical envelopes within disk drives can be developed to fit compact computer and other small products.
Specification SFF-8088 defines matable Compact Multilane Shielded connectors adopted for being used in laptop portable computer to connect small-size disk drives to a circuit board. The connectors comprise a plug connector connecting with the small-size drive and a header mounted on the circuit board. The plug connector defined in the specification comprises a pair of engagable metal housings together defining a receiving space therebetween, a circuit board received in the receiving space, a cable comprising a plurality of conductors electrically connecting with the circuit board, and a latching mechanism assembled to a top surface of the upper metal housing. The latching mechanism comprises an elongated T-shape latch member for latching with the header mentioned above and an actuating member cooperating with the latch member for actuating the latch member to separate from the header. The latch member is assembled to a rear portion of a base of the upper housing with latch portion exposed beyond a front portion of the base of the upper housing to locate above a tongue portion of the upper housing.
However, such elongated latch member is hard to be actuated by the actuating member, otherwise the latch member must have enough thickness or made by high-quality material having enough rigidity to achieve the goal of latching reliably and unlatching easily.
Hence, an improved plug connector is provided in the present invention to address the problems mentioned above and meet the current trend.
BRIEF SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a plug connector having a latching mechanism for achieving a reliable latching and an easy unlatching.
In order to achieve the above-mentioned object, a plug connector mating with a complementary connector in accordance with the present invention includes a housing, a circuit board, a latching mechanism and a metal shell. The housing includes a base defining a first and a second slots, and a tongue portion extending forwardly from the base for fitting with the complementary connector. The latching mechanism includes a pusher and a latch. The pusher includes a resilient beam disposed in the first slot and facing toward the second slot, a head portion connected with the resilient beam and provided with a resisting portion, and a depressing portion formed above the resilient beam. The latch has an inclined connecting portion engageable with the resisting portion and a latching portion. The metal shell is attached to the base and has a window for outward passage of the pressing portion. The resilient beam of the pusher is downwardly deformable in the second slot from an initial position to a final position to move the resisting portion relative to the inclined connecting portion of the latch, to thereby move the latching portion from a latching position to an unlatching position.
The latching mechanism comprises a pusher and a latch cooperated with each other to latch or unlatch the complementary connector. When the pusher is depressed, the latch would be driven from the latching position to the unlatching position automatically. When the pusher is released, the pusher would restore to the initial position automatically. It is easy to drive the whole latching mechanism to perform the latching and unlatching function, if only depressing the pusher or releasing the pusher. Additionally, the claws would latch the complementary connector reliably, since the latch restores itself to the latching position via a resilient restoring force provided by the resilient beam of the pusher.
Other objects, advantages and novel features of the invention will become more apparent from the following detailed description of the present embodiment when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of a plug connector in accordance with the present invention;
FIG. 2 is a view similar to FIG. 1 , taken from another aspect;
FIG. 3 is a partially assembled perspective view of the plug connector as shown in FIG. 1 , with the metal shell being removed;
FIG. 4 is an assembled perspective view of the plug connector as shown in FIG. 1 ;
FIG. 5 is a cross-sectional view taken along line 5 - 5 of FIG. 4 , when a latching mechanism is positioned in a latching position; and
FIG. 6 is a view similar FIG. 5 , showing the latching mechanism is positioned in an unlatching position.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made to the drawing figures to describe the present invention in detail.
Referring to FIGS. 1-3 , a plug connector 100 mating with a complimentary connector (not shown) in accordance with the present invention comprises a housing 1 , a latching mechanism 40 assembled to the housing 1 , an EMI gasket 6 attached to the housing 1 , a metal shell 5 partially covering the latching mechanism 40 , a plurality of screws 9 fixing the metal shell 5 on the housing 1 , a circuit board 7 disposed in the housing 1 , and a cable 8 electrically connected to the circuit board 7 . Optionally, the cable 8 could be replaced by any other structure in accordance with customer's requires.
Referring to FIGS. 1-2 , the housing 1 of the present invention comprises a base 11 and an elongated tongue portion 12 extending forwardly from the base 11 . The base 11 comprises a lower base 112 , an upper base 111 engaging with the lower base 112 and a receiving space (not shown) defined between the upper and lower bases 111 , 112 for partially retaining the circuit board 7 and the cable 8 in a common manner. Both upper and lower bases 111 and 112 are preferably die-casted.
The upper base 111 defines an elongated receiving slot 1111 having an arc-like shaped lower surface 1118 , a retaining recess 1116 concave from an upper surface of the upper base 111 . The receiving slot 1111 is father away from the tongue portion 12 , than the retaining recess 1116 is away from the tongue portion 12 . The upper base 111 comprises a transversely extending engaging recess 1112 , a receiving recess 1117 defined at a rear side of the upper base 111 , an insertion recess 1113 communicating with the retaining recess 1116 , four screw holes 1114 defined at four corners of the upper base 111 , and a pair of protruding tabs 1115 formed at a front edge of the retaining recess 1116 .
The circuit board 7 is formed with a plurality of conductive pads 71 for electrically connecting with the complementary connector. The tongue portion 12 has a receiving space (not labeled) defined therein for receiving a front portion of the circuit board 7 , and an opening 121 defined on an upper surface thereof for exposing the conductive pads 71 of the circuit board 7 . The tongue portion 12 has a plurality of flanges 122 formed on an upper surface thereof and a plurality of keyways 123 each defined adjacent to one flange 122 .
The latching mechanism 40 comprises a latch 2 and a pusher 3 assembled to the latch 2 . The latch 2 made of metal material is a cantilever-type member. The latch 2 comprises a transverse bar section 21 located in a vertical surface, a flat latching portion 22 located in a horizontal surface perpendicular to the vertical surface and an inclined connecting portion 23 connecting the bar section 21 and the latching portion 22 to provide resilient force to the latch 2 . The bar section 21 has a pair of side sections 212 extending downwardly from opposite sides thereof. Each side section 212 is formed with a plurality of barbs 2121 on outmost edge thereof. The flat latching portion 22 defines a pair of rectangular holes 221 adjacent to the connecting portion 23 , and a pair of claws 222 bending downwardly from opposite sides of the front edge thereof for clasping the complementary connector. The connecting portion 23 also defines a slit (not labeled) therein for adjusting spring force of the latch 2 through changing size and shape of the hole.
The pusher 3 comprises a rectangular resilient beam 31 and a head portion 34 connected with the resilient beam 31 . The resilient beam 31 comprises a ear portion 32 formed at a connecting portion of the resilient beam 31 and the head portion 34 , a tail portion 35 formed at a free end of the resilient beam 31 , a pressing portion 33 provided above the resilient beam 31 , and a neck portion 36 upholding the pressing portion 33 . The head portion 34 comprises a pair of symmetrically formed flanges 344 , a pair of blocks 342 respectively formed at a front portion of the flange 344 , a resisting portion 340 between the pair of blocks 342 , and an indentation 343 defined between the flanges 344 . The resisting portion 340 has an inclined face 341 inclining toward the indentation 343 .
The metal shell 5 comprises a top wall 51 , a pair of side walls 54 bending downwardly from the top wall 51 . The top wall 51 has a window 511 and four mounting holes 53 defined at four corner portions thereof.
Referring to FIGS. 1-3 , in assembly of the plug connector 100 , the cable 8 is soldered to the circuit board 7 . The circuit board 7 together with the cable 8 is partially sandwiched between the upper and lower bases 111 , 112 . The pusher 3 is assembled to the upper base 111 of the housing 1 , with the head portion 34 plunged in the retaining recess 1116 . The body portion 31 of the pusher 3 is disposed above the receiving slot 1111 , with the ear portion 32 attached to a front edge of the engaging recess 1112 and slidable in the engaging recess 1112 , and the tail portion 35 fixed in the receiving recess 1117 . The engaging recess 1112 and receiving recess 1117 could be regarded as a slot for receiving the ear portion 32 and the tail portion 35 . The latch 2 is inserted in the retaining recess 1116 , with the connecting portion 23 plunged in the indentation 343 of the pusher 3 . In conjunction with FIG. 5 , the resisting portion 340 contact with the connecting portion 23 to support the connecting portion 23 of the latch 2 . The side sections 212 are inserted in the insertion recess 1113 , with the barbs 2121 engaging with the insertion recess 1113 . Thus, the latch 2 is restricted from a front-to-back movement. The pair of rectangular holes 221 engage with the pair of protruding tabs 1115 .
In conjunction with FIGS. 4 and 5 , the EMI gasket 6 is attached to a front face of the base 11 of the housing 1 for shielding purpose. The metal shell 5 is fixed on the housing 1 , with each screw 9 inserted through the mounting hole 53 into the screw hole 1114 . The latching mechanism 40 is partially covered by the metal shell 5 , with the pressing portion 33 extending outward the metal shell 5 through the window 511 .
FIG. 5 illustrates the plug connector 100 located in a latching position and FIG. 6 illustrates the plug connector 100 located in an unlatching position. When the pressing portion 33 of the pusher 3 is downwardly depressed from an initial position to a final position, the resilient beam 31 of the pusher 3 is deformable downwardly toward the arc-like lower surface 1118 in the receiving slot 1111 . The head portion 34 retreats backwardly, with the resisting portion 340 sliding along the inclined connecting portion 23 of the latch 2 to move the connecting portion 23 . Since the bar section 212 is restricted from the front-to-back movement by the insertion recess 1113 , the connection portions 23 have been upheld by the resisting portion 340 . In conjunction with FIG. 3 , in such a process, the ear portion 32 of the pusher 3 slides backwardly and attached to a rear edge of the engaging recess 1112 . At the same time, the latching portion 22 together with the claws 222 move upwardly to the released position.
When the plug connector 100 is located in the unlatching position as shown in FIG. 6 , the complementary connector could be mounted onto or removed from the plug connector 100 . When the pressing portion 33 of the pusher 3 is released, the resilient beam 31 of the pusher 3 would restore itself from the final position to the initial position. Simultaneously, the pressing portion 33 together with the whole latching mechanism 40 revert to the latching position as shown in FIG. 5 . The complementary connector electrically connects with the conductive pads 71 of the circuit board 7 , with claws 222 clasping corresponding structure of the complementary connector.
The latching mechanism 40 comprises a pusher 3 and a latch 2 cooperated with each other to latch or unlatch the complementary connector. When the pusher 3 is operated, the latch 2 would be driven from the latching position to the unlatching position automatically. When the pusher 3 is released, the pusher 3 would restore to the initial position automatically. It is easy to drive the whole latching mechanism 40 to perform the latching and unlatching function, if only depressing the pusher 3 or releasing the pusher 3 . Additionally, the claws 222 would latch the complementary connector reliably, since the latch 2 restores itself to the latching position via the resilient restoring force provided by the resilient beam 31 of the pusher 3 .
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. | A plug connector ( 100 ) mating with a complementary connector includes a housing ( 1 ) having a base ( 11 ) defining a first slot and a second slot ( 1111 ), a latching mechanism ( 40 ) having a pusher ( 3 ) and a latch ( 2 ). The pusher includes a resilient beam ( 31 ) disposed in the first slot and facing toward the second slot, and a resisting portion ( 340 ). The latch has a latching portion ( 22 ) and an inclined connecting portion ( 23 ) engageable with the resisting portion. The resilient beam of the pusher is downwardly deformable in the second slot from an initial position to a final position to move the resisting portion relative to the connecting portion, to thereby move the latching portion from a latching position to an unlatching position. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims benefit under 35 U.S.C. §119(e) of and priority to U.S. Provisional Patent Application No. 61/348,565, filed May 26, 2010, and entitled “Reference Token Service”, which is incorporated herein by reference as if set forth herein in its entirety.
BACKGROUND
Typically, conventional data rotation services are tightly integrated within an application and perform services only for that particular application. A tightly integrated architecture might not be suitable for managing encrypted data in high-availability, multiple application software environments.
One problem with conventional crypto management services arises when transmitting or sharing data among separate-but-related applications. One application might not have the capability to decrypt data that has been encrypted by another application. For example, one application might use a different encryption technology than another application. If this is the case, then the applications must share data in unencrypted form.
Another problem with conventional crypto management services is that the extra step of decrypting and re-encrypting the data can cause extra load on the systems and reduce performance of an application that is using the same resources as the crypto management service. Such performance degradation may be unacceptable in the context of high-availability applications.
Yet another problem with conventional crypto management services is that the encrypted data is usually stored in the same location as unencrypted data. This makes handling data backups difficult when there are regulatory requirements for handling archived media containing encrypted data. Further, storing encrypted data in the same location as unencrypted data means the encrypted data is vulnerable to the same data corruption possibilities as the unencrypted data.
It would be beneficial to provide a centralized crypto system that performs various cryptography operations and stores encrypted data for one or more high-availability applications that share data. Such a software system may enable efficient centralized data management and encryption services among one or more high-availability applications.
BRIEF SUMMARY
Briefly described and according to one embodiment, a reference token service is herein described. In one embodiment, the reference token service receives raw data strings from trusted source applications associated with merchants or other users. Upon receipt of a given raw data string, the reference token service then identifies one or more reference token pools corresponding to a merchant that sent the raw data string, wherein each reference token pool includes a plurality of reference tokens with comprising formats and data structures compatible with the merchant. The raw data string is then sent to a crypto system for tokenization. The crypto system returns a crypto token to the reference token service, wherein the crypto token may not satisfy the specific formatting or data requirements of the merchant. The crypto token is then associated with a reference token corresponding to the merchant, and the reference token is provided to the merchant. The merchant is then able to use the reference token amongst various applications within the merchant's system to enable easy sharing and retrieval of the raw data string.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a schematic diagram of an illustrative embodiment of an enterprise software environment including a crypto system, according to one or more embodiments of the present disclosure.
FIG. 2A depicts a schematic diagram of an illustrative embodiment of an application transmitting data to a crypto system and receiving a token from the crypto system, according to one or more embodiments of the present disclosure.
FIG. 2B depicts a schematic diagram of an illustrative embodiment of an application transmitting data and an application-defined token to a crypto system and receiving a status response from the crypto system, according to one or more embodiments of the present disclosure.
FIG. 3 depicts a schematic diagram of an illustrative embodiment of an application receiving application data stored on a crypto system, according to one or more embodiments of the present disclosure.
FIG. 4 depicts a schematic diagram of an illustrative embodiment of an application sharing a token with another application, according to one or more embodiments of the present disclosure.
FIG. 5 depicts a schematic diagram of an illustrative embodiment of an application receiving application data stored on a crypto system using a shared token, according to one or more embodiments of the present disclosure.
FIG. 6 depicts a schematic diagram of an illustrative embodiment of an algorithm implementing a rotation service, according to one or more embodiments of the present disclosure.
FIG. 7 depicts an illustrative reference token service interposed between an enterprise application and the crypto system, according to one or more embodiments of the present disclosure.
FIG. 8 depicts an illustrative reference token service interposed between an application and the crypto system, according to one or more embodiments of the present disclosure.
FIG. 9 depicts a first security interface interposed between an application and the reference token system and a second security interface interposed between the reference security system and the crypto system, according to one or more embodiments of the present disclosure.
DETAILED DESCRIPTION
It is to be understood that the following disclosure describes several exemplary embodiments for implementing different features, structures, or functions of the invention. Exemplary embodiments of components, arrangements, and configurations are described below to simplify the present disclosure, however, these exemplary embodiments are provided merely as examples and are not intended to limit the scope of the invention. Additionally, the present disclosure may repeat reference numerals and/or letters in the various exemplary embodiments and across the Figures provided herein. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various exemplary embodiments and/or configurations discussed in the various Figures. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact. Finally, the exemplary embodiments presented below may be combined in any combination of ways, i.e., any element from one exemplary embodiment may be used in any other exemplary embodiment, without departing from the scope of the disclosure.
Additionally, certain terms are used throughout the following description and claims to refer to particular components. As one skilled in the art will appreciate, various entities may refer to the same component by different names, and as such, the naming convention for the elements described herein is not intended to limit the scope of the invention, unless otherwise specifically defined herein. Further, the naming convention used herein is not intended to distinguish between components that differ in name but not function. Further, in the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.” All numerical values in this disclosure may be exact or approximate values unless otherwise specifically stated. Accordingly, various embodiments of the disclosure may deviate from the numbers, values, and ranges disclosed herein without departing from the intended scope. Furthermore, as it is used in the claims or specification, the term “or” is intended to encompass both exclusive and inclusive cases, i.e., “A or B” is intended to be synonymous with “at least one of A and B,” unless otherwise expressly specified herein.
In describing selected embodiments, various objects or components may be implemented as computing modules. These modules may be general-purpose, or they may have dedicated functions such as memory management, program flow, instruction processing, object storage, etc. The modules can be implemented in any way known in the art. For example, in one embodiment a module is implemented in a hardware circuit including custom VLSI circuits or gate arrays, off-the-shelf semiconductors such as logic chips, transistors, or other discrete components. One or more of the modules may also be implemented in programmable hardware devices such as field programmable gate arrays, programmable array logic, programmable logic devices or the like.
In an exemplary embodiment, one or more of the modules are implemented in software for execution by various types of processors. An identified module of executable code may, for instance, include one or more physical or logical blocks of computer instructions that may, for instance, be organized as an object, procedure, or function. Further, the executables of an identified module need not be physically located together, but may include disparate instructions stored in different locations that, when joined logically together, include the module and achieve the stated purpose for the module. A “module” of executable code could be a single instruction, or many instructions, and may be distributed over several different code segments, among different programs, and across several memory devices. Similarly, operational data may be identified and illustrated in association with one or more modules, and may be embodied in any suitable form and organized within any suitable type of data structure. The operational data may be collected as a single data set, or may be distributed over different locations including over different storage devices, and may exist, at least partially, as electronic signals on a system or network.
In some embodiments, higher-level components may be used as modules. For example, one module may include an entire computer acting as a network node. Another module may include of an off-the-shelf or custom program, such as a database management system. These higher-level modules may be decomposable into smaller hardware or software modules corresponding to different parts of a software program and identifiable chips (such as memory chips, ASICs, or a CPU) within a computer.
One type of module is a “network.” A network module defines a communications path between endpoints and may include an arbitrary amount of intermediate modules. A network module may encompass various pieces of hardware, such as cables, routers, and modems, as well the software necessary to use that hardware. Another network module may encompass system calls or device-specific mechanisms such as shared memory, pipes, or system messaging services. A third network module may use calling conventions within a computing module, such as a computer language or execution environment. Information transmitted using the network module may be carried upon an underlying protocol, such as HTTP, BXXP, or SMTP, or it may define its own transport over TCP/IP, IPX/SPX, Token Ring, ATM, etc. To assure proper transmission, both the underlying protocol as well as the format protocol may split the information into separate pieces, wrap the information in an envelope, or both. Further, a network module may transform the data through the use of one or more computing modules.
FIG. 1 depicts a schematic diagram of an illustrative embodiment of an enterprise software environment 100 including a crypto system 101 , according to one or more embodiments of the present disclosure. The crypto system 101 may include a crypto database 102 , a cryptography module 106 , memory 110 , a computer readable medium 111 , an application interface 116 , and a data rotation service 140 .
In at least one embodiment, the crypto database 102 may be a MICROSOFT SQL SERVER implementation operating on a MICROSOFT WINDOWS-based operating system. In another embodiment, the crypto database 102 may be an ORACLE database operating on a MICROSOFT WINDOWS-based operating system. In yet another embodiment, the crypto database 102 may be a PostgreSQL database operating on a LINUX-based operating system. In yet another embodiment, the crypto database 102 may operate on a UNIX-based operating system. It should be understood that the foregoing embodiments are merely examples and that the crypto database 102 may be any database implementation operating on any operating system.
The cryptography module 106 may run on one computer, or it may run on multiple computers for purposes of load balancing and failover. In at least one embodiment, the cryptography module 106 may implement PCI DSS-compliant technology based on the National Institute of Standards and Technology (NIST) Advanced Encryption Standard (AES) cryptography technology. In another embodiment, the cryptography module 106 may implement RSA encryption technology, such as the RC4 algorithm. In yet another embodiment, the cryptography module 106 may implement MICROSOFT cryptography technology, such as the MICROSOFT Crypto API or any other MICROSOFT Cryptographic Service Provider (CSP). In yet another embodiment, the cryptography module 106 may implement protocols that may be used to communicate with encryption hardware 108 . For example, the cryptography module 106 may implement the RSA PKCS 11 API. The foregoing are merely examples of cryptography technology that may be used in embodiments of the present disclosure and are not meant to be limiting.
In at least one embodiment, the crypto system 101 may be communicably coupled to encryption hardware 108 , such as a network-connected hardware security module (HSM). Further, one or more applications 120 A-C may be communicably coupled to the crypto system 101 . Three applications 120 A-C are depicted in FIG. 1 , however, any number of applications 120 A-C may exist. The applications 120 A-C may be high-availability systems that require minimal down-time.
Each application 120 A-C may be communicably coupled to one or more application databases 130 A-C. In at least one embodiment, the application databases 130 A-C may be MICROSOFT SQL SERVER implementations operating on a MICROSOFT WINDOWS 2003 SERVER operating system. In another embodiment, the application databases 130 A-C may be ORACLE databases operating on a MICROSOFT WINDOWS 2003 SERVER operating system. In yet another embodiment, the application databases 130 A-C may be PostgreSQL databases operating on a LINUX-based operating system. In yet another embodiment, the application databases 130 A-C may operate on a UNIX operating system. It should be understood that the application databases 130 A-C may be any database implementation operating on any operating system, and the foregoing embodiments are not meant to be limiting.
In at least one embodiment, the applications 120 A-C and the application databases 130 A-C may not store sensitive data, such as credit card information or personally identifiably information (PII), locally. Rather, the sensitive data may be stored in the crypto database 102 of the crypto system 101 .
An application interface 116 may enable data to be transferred between an application 120 A-C and the crypto system 101 . Possible application interfaces 116 may include, without limitation, Remote Procedure Calls (RPC) and web services. For example, in one embodiment, the RPC application interface may be a Remote Function Call (RFC), which is an application interface used by SAP systems.
In at least one embodiment, the crypto system 101 may perform centralized data management and/or various cryptographic operations for the applications 120 A-C. For example, the crypto system 101 may conduct cryptography functions, such as encryption, mass encryption, decryption, and data rotation. In at least one embodiment, the cryptography module 106 of the crypto system 101 may receive one or more inputs from an application 120 A-C via the application interface 116 . The inputs may include instructions, a key, and/or data in encrypted or unencrypted form. Upon receiving an input, the cryptography module 106 may perform operations on the data using the key in accordance with the instructions. For example, if data is accompanied by encryption instructions, then the cryptography module 106 may encrypt the data with the key. The encrypted data may be transmitted to the crypto database 102 where it may be stored. In another embodiment, the crypto module 106 may retrieve the encrypted data from the crypto database 102 and decrypt the data. The decrypted data may then be transmitted back to the appropriate application 120 A-C.
An advantage of storing encrypted data on a centralized storage system, such as the crypto system 101 is that the centralized storage system may have stronger access control and support for PCI DSS-compliant backups. Another advantage is that a single purge and archival policy may be used for all sensitive data. Yet another advantage is that a wide range of enterprise encryption needs may be supported with the server. Yet another advantage is that different cryptography keys may be assigned to collections of applications with varying data rotation and archival policies. Yet another advantage is that multiple encryption technologies may be simultaneously supported, including, without limitation, software and hardware based cryptography technologies.
The crypto system 101 may periodically perform a key rotation operation. In at least one embodiment, the keys may be stored in the cryptography module 106 , and references to the keys may be stored in the crypto database 102 . A key rotation operation may include replacing the current active encryption keys with a new active encryption keys. When the crypto system 101 performs a key rotation, the crypto system 101 may also perform a data rotation operation corresponding to the key rotation. In at least one embodiment, the rotation operations occur at fixed intervals. For example, the crypto system 101 may be configured to perform the rotation operations during low-volume periods. In another embodiment, a user of the crypto system 101 may select when to initiate a rotation operation. For example, a user may submit a data rotation operation command to the crypto system 101 from a terminal (not shown) that is communicably coupled to the crypto system 101 .
The data rotation service 140 may monitor the crypto system 101 and perform data rotation operations corresponding to key rotation operations. In at least one embodiment, the data rotation service 140 may operate on a single computer that is communicably coupled to the crypto database 102 . In another embodiment, the data rotation service 140 may operate on more than one system, thereby allowing clusters of systems to perform operations on partitions of a total data set. It will be understood and appreciated by those of ordinary skill in the art that although the data rotation service 140 is illustrated in FIG. 1 as a component of the crypto system 101 , in various other embodiments the data rotation service may be external to the primary crypto system, and may interact with the crypto system via a web service (WS) interface (for example). Accordingly, embodiments of the present system are not limited to the specific embodiments illustrated and discussed herein.
Data rotation may include decrypting data that was encrypted with a previously active key (“stale” data) and re-encrypting the decrypted data with a currently active key to produce “fresh” data. Thus, data rotation ensures that the data stored in the crypto database 102 is always fresh, i.e., encrypted with the currently active key. The data rotation service 140 may utilize the cryptography module 106 to decrypt and encrypt data.
Multiple references to decryption keys may be stored in the crypto database 102 , the memory 110 , and/or the computer readable medium 111 . For example, the crypto database 102 , the memory 110 , and/or the computer readable medium 111 may include references to decryption keys capable of decrypting stale data. Storing references to decryption keys enables the crypto system 101 to continue processing application 120 A-C requests for data even if data rotation is not yet complete. For example, during a data rotation, a partition may contain a combination of stale data and fresh data. Because the crypto system 101 has access to previously active encryption keys and the currently active encryption keys, the crypto system 101 may decrypt both stale data and fresh data. Thus, the crypto system 101 may continue to respond to the application requests for data even if data rotation is not yet complete.
In at least one embodiment, after the application data is encrypted by the cryptography module 106 and stored in the crypto database 102 , the crypto system 101 may generate one or more tokens corresponding to the application data. The tokens may be transmitted to the applications 120 A-C. The applications 120 A-C may store the tokens either locally or in the application databases 130 A-C and later use the tokens in place of the application data.
In at least one embodiment, a token is a text string that is 25 characters in length. A sample token is as follows: -VVVV-SSSS-NNNNNNNNNNNNNC.
In the exemplary embodiment, characters 0, 5, and 10 are a dash “-”. Characters 1 through 4 (represented by “V”) correspond to a base-16 encoded integer value that may be used to determine the code path to take when evaluating the token during decryption requests. If the length of the unencrypted (or raw) string is between 1 and 4 characters, then characters 6 through 9 (represented by “S”) may be blank spaces. If the length of the unencrypted string is more than 4 characters, characters 6 through 9 may represent the last four characters of the unencrypted string. In at least one embodiment, the unencrypted string may be a credit-card number, and characters 6-9 may represent the last four digits of the credit-card number. Zero length strings may not be encrypted.
Characters 11 through 23 (represented by “N”) may be a base-32 representation of a 64-bit unsigned number. In at least one embodiment, each character 11 through 23 may be a base 32 value. In at least one embodiment, characters 11-23 may represent a unique identifier that is associated with the encrypted string in the crypto database 102 . In other words, characters 11 through 23 may be used to locate the encrypted string in the crypto database 102 . Character 24 may be a check digit that is calculated by adding the values of the base-32 characters and representing that value as a modulo 32 number. The tokens may be represented using text-based markup languages, such as XML, to facilitate the transmission of tokens between disparate platforms.
According to an additional embodiment, “flextokens” may be used wherein the format of the token is controlled by a format specifier similar to that used for a printf C API. Use of such “flextokens” allows for easy creation of new formats as needed.
The tokens described herein may provide several benefits. One benefit is that the structure of a token generated by the crypto system 101 may include the last four characters of the encrypted data in unencrypted form. This feature is particularly useful when the encrypted data involves storing a credit card number. For example, in one embodiment, the token may include the last four digits of the encrypted credit card number in unencrypted form. In such an embodiment, the applications 120 A-C do not need to submit a request to the crypto system 101 for unencrypted data if the applications 120 A-C only need the last four digits of the credit card number. A human operator would be able to read the last four digits of the credit card number simply by examining the token. Moreover, the ability to use application-defined tokens provides flexibility when using applications 120 A-C or application databases 130 A-C that are legacy systems that do not support the storage of a token defined by the crypto system 101 .
FIG. 2A depicts a schematic diagram of an illustrative embodiment of an application 120 A transmitting data to a crypto system 101 and receiving a token from the crypto system 101 , according to one or more embodiments of the present disclosure. In at least one embodiment, the application 120 A may transmit data to the crypto system 101 , as shown at 202 . Data may be transmitted between the application 120 A and the crypto system 101 via the application interface 116 ( FIG. 1 ). The crypto system 101 may receive the data and encrypt the data using the cryptography module 106 ( FIG. 1 ). After the data has been encrypted, the crypto system 101 may transmit the encrypted data to the crypto database 102 for storage, as shown at 204 . The crypto system 101 may generate a token corresponding to the encrypted data, and the token may be transmitted to the application 120 A, as shown at 206 . After receiving the token, the application 120 A may store the token in the application database 130 A, as shown at 208 .
FIG. 2B depicts a schematic diagram of an illustrative embodiment of an application 120 A transmitting data and an application-defined token to a crypto system 101 and receiving a status response from the crypto system 101 , according to one or more embodiments of the present disclosure. In at least one embodiment, the application 120 A may transmit data and an application-defined token to the crypto system 101 , as shown at 650 . The crypto system 101 may receive the data and encrypt the data using the cryptography module 106 ( FIG. 1 ). An internal reference may be generated that associates the encrypted data with the application-defined token. The crypto system 101 may transmit the encrypted data, the application-defined token, and the internal reference to the crypto database 102 for storage, as shown at 652 . The crypto system 101 may transmit a status response to the application 120 A, as shown at 654 .
In certain situations, using an application-defined token, as described with respect to FIG. 2B , may be preferred to using a token defined by the crypto system 101 , as described with respect to FIG. 2A . For example, an application 120 A may be unable to store a token generated by the crypto system 101 . This may occur if the token generated by the crypto system 101 is too large for the fields defined in a table of an application database 130 A ( FIG. 1 ), as the application database 130 A-C may be part of a legacy system that does not support adding extra columns to its internal tables.
FIG. 3 depicts a schematic diagram of an illustrative embodiment of an application 120 A receiving application data stored on a crypto system 101 , according to one or more embodiments of the present disclosure. In at least one embodiment, the application 120 A may retrieve a token from the application database 130 A, as shown at 302 . In another embodiment, instead of retrieving a token from the application database 130 A, the application 120 A may generate an application-defined token. The application 120 A may transmit the token to the crypto system 101 , as shown at 304 . The token may be transmitted from the application 120 A to the crypto system 101 via the application interface 116 ( FIG. 1 ). The crypto system 101 may receive the token and retrieve the encrypted data corresponding to the token from the crypto database 102 , as shown at 306 . The crypto system 101 may decrypt the encrypted data using the cryptography module 106 ( FIG. 1 ). The crypto system 101 may then return the unencrypted data to the application 120 A, as shown at 308 .
In at least one embodiment, more than one application-defined token may be associated with an encrypted value. For example, the encrypted value may be a credit card number, and one application-defined token may be the social security number of the credit card holder, and a second application-defined token may be an employee identification number of the credit card holder. An Application 120 A-C may then submit either the social security number or the employee identification number as a token to the retrieve the encrypted information from the crypto system 101 .
FIG. 4 depicts a schematic diagram of an illustrative embodiment of an application 120 A sharing a token with another application 120 B, according to one or more embodiments of the present disclosure. In at least one embodiment, the application 120 A may transmit data to the crypto system 101 , as shown at 402 . Data may be transmitted between the application 120 A and the crypto system 101 via the application interface 116 ( FIG. 1 ). The crypto system 101 may receive the data and encrypt the data using the cryptography module 106 ( FIG. 1 ). After the data has been encrypted, the crypto system 101 may transmit the encrypted data to the crypto database 102 for storage, as shown at 404 . The crypto system 101 may generate a token associated to the encrypted data, and the token may be transmitted to the application 120 A, as shown at 406 . After receiving the token, the application 120 A may store the token in the application database 130 A, as shown at 408 . In at least one embodiment, the application 120 A may share the token received from the crypto system 101 with the application 1208 , as shown at 410 . After the application 120 B receives the shared token from the application 120 A, the application 120 B may store the shared token in application database 130 B, as shown at 412 .
FIG. 5 depicts a schematic diagram of an illustrative embodiment of an application 120 B receiving application data stored on a crypto system 101 using a shared token, according to one or more embodiments of the present disclosure. In at least one embodiment, the application 120 B may retrieve a shared token from application database 130 B, as shown at 502 . For example, the application 120 B may have originally received the shared token from the application 120 A, as shown in FIG. 4 . The application 120 B may transmit the shared token to the crypto system 101 , as shown at 504 . The shared token may be transmitted from application 120 B to the crypto system 101 via the application interface 116 ( FIG. 1 ). The crypto system 101 may receive the shared token and retrieve the encrypted data corresponding to the shared token from the crypto database 102 , as shown at 506 . The crypto system 101 may decrypt the encrypted data using the cryptography module 106 ( FIG. 1 ). The crypto system 101 may then transmit the unencrypted data to the application 120 B, as shown at 508 .
FIG. 6 depicts a schematic diagram of an illustrative embodiment of an algorithm 600 implementing a rotation service, according to one or more embodiments of the present disclosure. A function of the algorithm 600 is to rotate data stored in the crypto database 102 . The algorithm 600 may receive one or more inputs, which may include a reference to an active encryption key 602 , and output a decryption status 603 .
The algorithm 600 may reserve a partition containing stale data stored in the crypto database 102 , as shown at 606 . Each partition may have an associated partition reservation time. The partition reservation time reflects when the partition was last reserved. When the algorithm 600 reserves a partition, the algorithm 600 may also update the partition reservation time.
The algorithm 600 may retrieve stale values in the reserved partition from the crypto database 102 ( FIG. 1 ), as shown at 608 . The algorithm 600 may store the stale values in a data structure (not shown). The data structure may be a one-dimensional array. In at least one embodiment, while retrieving stale values, the algorithm 600 may not modify the reference date of the stale values as they are read. In another embodiment, if the crypto database 102 automatically updates the reference date of the stale values as they are read, the algorithm 600 may note the original reference dates of the stale values before they are read and overwrite the updated reference dates with the original reference dates, as shown at 609 .
The algorithm 600 may include a data rotation loop 610 . The data rotation loop 610 may decrypt stale values and encrypt the stale values with the current active encryption key to produce fresh values. The algorithm 600 may decrypt a stale value with a decryption key, as shown at 612 . If decryption of the stale value is successful, the algorithm 600 may encrypt the decrypted stale value with the current active encryption key to produce a fresh value, as shown at 614 . In at least one embodiment, an attempt to decrypt a stale value may fail. For example, a decryption key corresponding to the stale value may not be available on the crypto system 101 , or the stale value may be corrupt. Each time a decryption attempt fails, a decryption failure count variable 613 is incremented by one.
The atomic steps 615 may include a verifying step 616 and a refresh step 618 . In at least one embodiment, the atomic steps 615 must all complete successfully, and if the atomic steps do not complete successfully, the effects of each atomic step are undone. The algorithm 600 may verify the partition is reserved and update the partition reservation time, as shown at 616 . If the partition is no longer reserved, the atomic steps 615 fail. If the partition is still reserved, the algorithm 600 may replace the stale value in the crypto database 102 with a fresh value, as shown at 618 . If refreshing the stale value fails, then the atomic steps 615 fail.
In at least one embodiment, the algorithm 600 may not modify the reference date of the stale value when it is refreshed at 618 . In another embodiment, the crypto database 102 ( FIG. 1 ) may automatically update the reference date of the stale value when it is refreshed. When this occurs, the algorithm 600 may note the original reference date of the stale value before replacing the stale value with the fresh value, and overwrite the updated reference date with the original reference date, as shown at 619 .
The algorithm 600 may release the reserved partition, as shown at 620 . The algorithm 600 may then output the decryption status 603 , as shown at 622 . The output may include a decryption failure count 613 , and then the decryption failure count variable 613 may be reset to zero. The algorithm 600 may repeat until all stale data in each partition has been processed.
It should be understood that the above algorithm 600 is merely one embodiment of the present disclosure. Accordingly, other implementations using different data structures and modules may be used. For example, in one embodiment of the algorithm 600 , only a subset of the stale values in a partition is retrieved in the data retrieval step 608 . In such an embodiment, the algorithm 600 may repeat, each time processing a different subset of stale values in the partition until at least one attempt has been made to refresh each stale value in the partition. The algorithm 600 may then be repeated to process other partitions. The algorithm 600 may repeat until all stale data in all partitions is replaced with fresh data.
FIG. 7 depicts an illustrative reference token service 720 interposed between an application 710 and a crypto system 730 , according to one or more embodiments of the present disclosure. It will be understood and appreciated that, in at least one embodiment, the application 710 is analogous or corresponds to an application 120 A-C described previously, and the crypto system 730 is analogous or corresponds to a crypto system 101 described previously. In at least one embodiment, a token generated by the crypto system 730 (i.e., a “crypto token”) may include 25 characters: a 14 character alphanumeric core token (13 meaningful characters and a check character) and 11 characters of format and version detail. Each meaningful character may be one of 36 alphanumeric characters. Thus, the 13 meaningful characters in the core token may produce a token space of 36^13 which may effectively ensure no token wraparound/duplication for the life of the product. In other embodiments in which the characters relate to a 64 bit signed integer, the token space is 2^63. However, the data fields of some applications 710 may be too small to accommodate the tokens generated by the crypto system 730 . Moreover, the data fields of some applications 710 may have field type restrictions, e.g., numeric characters only, specific format requirements, or validation requirements, such that tokens generated by the crypto system 730 may not be received and stored by the applications 710 . A reference token service 720 may act as an intermediary between an application 710 and the crypto system 730 . The reference token service 720 may generate tokens that may be specifically formatted to meet the requirements of the application 710 . In another embodiment, the reference token service 720 may reformat existing tokens to meet the requirements of the application 710 .
The reference token service 720 may have a high runtime performance and high availability. Furthermore, the reference token service 720 may have a strong authentication and access control system. The reference token service 720 may also be adapted to provide services to multiple merchants, and support multiple formats for each merchant. Moreover, the reference token service 720 may be available on demand or be an on-premise service.
FIG. 8 depicts an illustrative reference token service 820 interposed between an application 810 and the crypto system 860 , according to one or more embodiments of the present disclosure. Similarly to the components described in connection with FIG. 7 , it will be understood and appreciated that, in at least one embodiment, the application 810 is analogous or corresponds to an application 120 A-C or 710 described previously, and the crypto system 860 is analogous or corresponds to a crypto system 101 or 730 described previously. High bandwidth communication and low latency may exist between the reference token system 820 and the crypto system 860 . In at least one embodiment, the reference token service 820 may include a security interface 830 , one or more merchant data sets 840 A-D (four are shown), and one or more reference token pools 850 A-J (ten are shown) associated with each merchant data set 840 A-D. In at least one embodiment, the security interface 830 may include an Apache http server, a web service, and a WS-security ACL program. The web services and WS-security program may provide strong authentication and access control.
In at least one embodiment, the reference token service 820 may include one or more data sets 840 A-D, each assigned to a particular merchant. For example, a first data set 840 A may be assigned to a first merchant, and a second data set 840 B may be assigned to a second merchant. Although four data sets 840 A-D are shown, any number of data sets 840 A-D may be stored in the reference token service 820 . Additionally, as will be understood and appreciated, although the term “merchant” is used herein, it will be understood that end users of the present system need not be “merchants,” but may represent any entity that requires use of tokens in connection with data security.
In at least one embodiment, each data set 840 A-D may include one or more reference token pools 850 A-J. For example, the first data set 840 A may include two reference token pools 850 A,B, and the second data set 840 B may include four reference token pools 850 C-F. Any number of reference token pools 850 A-J may be associated with each data set 840 A-D. Each reference token pool 850 A-J may correspond to a particular type and/or format of data designated by the merchant. For example, reference token pool 850 A may correspond to social security numbers, and reference pool 850 B may correspond to credit card numbers.
One or more reference tokens may be pre-generated and stored in each reference token pool 850 A-J. In at least one embodiment, a format specific executable or code may be used to populate a reference token pool 850 A-J with pre-generated reference tokens. The format specific executable may be used to generate reference tokens having specific token attributes provided by the merchant. In at least one embodiment, token attributes may include the total length of the token, i.e., the number of characters, whether the characters are numeric or alphanumeric, whether any of the characters are embedded characters containing any of the original data, or any other fixed formatting requested by the merchant. For example, a merchant may design or request an executable that populates a reference token pool 850 A-J with pre-generated reference tokens that have less than 25 characters, thereby allowing the reference tokens to be received and stored by an application 810 that is unable to store 25 character tokens.
In at least one embodiment, a format specific executable may exist for each reference pool 850 A-J. For example, a first format specific executable may be used to pre-generate reference tokens in a first reference pool 850 A corresponding to social security numbers and having nine numeric characters, and a second format specific executable may be used to pre-generate tokens in a second reference pool 850 B corresponding to credit card numbers and having 16 alphanumeric characters. In at least one embodiment, the pre-generation of tokens is an off-line administrative process. In another embodiment, the pre-generation of tokens is conducted in the background while the reference token system 820 is on-line.
In operation, a merchant may use the application 810 to make a call to the reference token service 820 and request the tokenization of a raw string of data. The raw string may include between one and twenty five characters. In at least one embodiment, the raw string may include, but is not limited to, data representing social security numbers, credit card numbers, personally identifiable information, human resources information, medical records, prescription numbers, bank account numbers, or other data to be protected.
The security interface 830 may receive the call from the application 810 , and the WS security program may authenticate the caller as a valid end-point by checking a WS security certificate belonging to the merchant and/or application 810 . The WS security certificate may also identify the data set 840 A-D within the reference token service 820 assigned to the merchant. The WS security certificate may also define the allowable operations, which may include, but are not limited to, tokenization, detokenization, deleting a token, and checking the existence of a token or data. In at least one embodiment, the WS security certificate may include a X.509 certificate.
If the caller is authenticated, the reference token service 820 may transmit the raw string to the crypto system 860 for tokenization. The crypto system 860 may encrypt the raw string and generate a crypto token. As referred to herein, a “crypto token” is a token generated by the crypto system 101 , 730 or 860 , and that may or may not meet specific formatting requirements of an end application. The encrypted raw string may be stored in a database in the crypto system 860 , such as the crypto database 102 shown in FIG. 1 . In at least one embodiment, the crypto token may include twenty five characters. The crypto token may be transmitted to the reference token service 820 where it may be persisted (stored in a database) by the reference token service 820 .
The application 810 may identify a particular reference token pool 850 A-J from which to select a reference token with pre-generated attributes. A reference token from the specified reference token pool 850 A-J may be associated with the crypto token that is received and persisted, and the reference token may then be transmitted to the application 810 . In at least one embodiment, the reference token may be modified before being transmitted to the application 810 . In an exemplary embodiment, the pre-generated reference token may have predetermined attributes corresponding to a social security number, such as nine numeric characters. The reference token may be modified such that the last four characters of the reference token are embedded with the last four digits of the social security number. In another exemplary embodiment, the pre-generated reference token may have predetermined attributes corresponding to a credit card number, such as sixteen alphanumeric characters. The reference token may be modified such that the last four characters of the reference token are embedded with the last four digits of the original credit card number. The foregoing embodiments are merely examples of modified reference tokens are not meant to be limiting.
After a merchant receives a reference token, the reference token may be transmitted (shared) from one application 120 A to another application 120 B, as seen in FIG. 4 . A second application 1208 may then retrieve the raw data from the crypto system 960 , as seen in FIG. 5 .
In at least one embodiment, a masked value may also be transmitted from the reference token service 820 to the application 810 . The masked value may provide a convenient way for a merchant to retrieve and submit a desired portion of data so that a merchant does not have to retrieve a reference token from an application database or retrieve the encrypted data from the crypto system 860 . The masked value may include one or more characters from the raw string along with one or more masking characters. In an exemplary embodiment, the masked value may include a portion of a credit card number, such as the last four digits. The masked value may also include masking characters, such as the “*” character, that replace the remaining credit card numbers. A sample masked value may look like: ************1234.
In at least one embodiment, a status indicator may be transmitted from the crypto system 860 or the token reference service 820 to the application 810 . Possible status indications may include successful, failure—token exists (in the crypto system 860 ), failure—invalid parameters (like no such token type), failure—reference token system 820 unavailable or unreachable, and failure—reference token unavailable.
A merchant may also be able to detokenize, i.e., return the reference token in exchange for the original raw string of data, delete a particular token, or check for the existence of a particular token. In at least one embodiment, a merchant may want exchange the reference token for the original raw string of data. The merchant may place a call from the application 810 to the reference token service 820 . The security interface 830 may receive the call from the application 810 . The WS security program may authenticate the caller as a valid end-point by checking a WS security certificate belonging to the merchant and/or application 810 . The WS security certificate may also identify the data set 840 A-D within the reference token service 820 assigned to the merchant. After the application 810 has been authenticated, it may transmit the reference token to the reference token service 820 . In at least one embodiment, the reference token will be stored in the reference token pool 850 A-F from which it was originally retrieved so that it may be used again. In another embodiment, the reference token may be deleted after it identifies the crypto token with which it is associated. In another embodiment, the crypto token may be re-formatted by the executable for a particular reference token pool 850 A-J and placed back in the pool 850 A-J.
The reference token service 820 may retrieve the crypto token associated with the reference token. The crypto token may be transmitted to the crypto system 860 . The crypto system 860 may decrypt the encrypted raw string associated with the crypto token, thus producing the original raw string and transmit the original raw string to the application 810 .
FIG. 9 depicts a first security interface 920 interposed between an application 910 and the reference token system 930 and a second security interface 940 interposed between the reference token system 930 and the crypto system 950 , according to one or more embodiments of the present disclosure. In at least one embodiment, at least one of the first security interface 920 and the second security interface 940 may include an Apache http server, a web service, and a WS security program.
The foregoing has outlined features of several embodiments so that those skilled in the art may better understand the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions and alterations herein without departing from the spirit and scope of the present disclosure. | A reference token service (RTS) is disclosed. Generally, the RTS receives sensitive data items from trusted source applications associated with particular merchants. Upon receipt of a particular sensitive data item from a particular merchant, the RTS identifies one or more reference token pools corresponding to the merchant. Each reference token pool includes a plurality of reference tokens comprising formats and data structures corresponding to sensitive data items and compatible with the merchant. The RTS receives a crypto token associated with the sensitive data item which may not conform to the merchant's formatting or data requirements. The RTS associates the crypto token with a reference token corresponding to the merchant, which is provided to the merchant for sharing and retrieval of the sensitive data item amongst the merchant's various applications. | 6 |
BACKGROUND OF THE INVENTION
This invention relates generally to well pumping units and more specifically to a simplified and improved drive for imparting reciprocating movement to the polish rod of the pump. The invention includes an improved and reliable reversing mechanism which provides a dwell period between an upstroke and a downstroke wherein the power source is in an off position. The dwell period may be easily adjusted to suit design and field conditions. Thus, the usual shock experienced during stroke exchange from an upstroke to a downstroke is cushioned to thereby reduce wear and tear on parts and increase the life of the unit. Additional cushioning is provided by a winding drum structure which slows reciprocation of the unit, at the point of exchange from a downstroke to an upstroke.
The invention has particular utility with a long stroke, well pump employing an electric motor as the power source. I have developed such a well pumping unit, as herein disclosed, which includes a tower mounted on a base platform, a source of power in the form of an electric motor, a winding drum on the base platform driven from the electric motor, and a lift belt made of conveyor belting from the winding drum up to the top of the tower and over a spool mounted thereon and then extended downwardly and secured to the polish rod of the otherwise conventional well pump. A counterbalance or counterweight is attached to that portion of the drive belt between the spool and the winding drum so that power requirements are kept to a minimum. An idler spool is provided in the tower and that portion of the lift belt between the counterweight and the winding drum is trained beneath the idler pulley or spool so as to eliminate any side to side movement of the counterweight during operation of the pump. The reversing mechanism and winding drum are arranged and configured to minimize the shock of exchange between an upstroke and a downstroke, at which time the power source for the winding drum reverses direction, and between a downstroke and an upstroke, at which time the lift belt is rewound upon the drum, respectively.
A brief description of the background of development of well pumping units is appropriate. In the early life of a well, reservoir pressure alone may be sufficient to lift the oil to the surface, providing local regulatory authorities permit such a procedure. However, such pressure is eventually exhausted whereupon the oil must be pumped to the surface. The most common variety of pump in use is a walking beam pump having a nominal stroke of approximately seven to 10 feet. A walking beam pump is suitable for shallow wells, but such a pump becomes inefficient and eventually inoperable with wells which are one, two or miles deep. Specifically, rod stretch may become equal to stroke distance, thus rendering a walking beam pump completely inoperable when used with a very deep well.
Thus, long stroke, well pumping units particularly useful in deep wells, have been developed, some having stroke lengths of thirty-two feet or more. An example of such a prior art long stroke pumping unit is the "Oilwell" Long Stroke Pumping Unit, made by Oilwell, a division of United States Steel. The unit includes a central tower having multiple guides to stabilize the structure, a complex multi-strand cable crown block assembly suspending the rod string, a variable capacity counterweight, and a prime mover. A wire line drum is used having a helix track operative during exchange from a downstroke to an upstroke to slow wire line travel somewhat, increase mechanical advantage on the well side of the pump, and thus reduce the shock of stroke reversal somewhat. This unit is both complex and expensive.
An improved wire line deep well pumping apparatus is disclosed and claimed in my own prior U.S. Pat. No. 3,248,958. A basic yo-yo variety of long stroke pumping unit discussed therein has a power system in which a cycle of windup (during pump upstroke) and payout (during pump downstroke) is accomplished without need for winding drum reversal; thus, the power source of the unit is reversed only after a full cycle of operation rather than with each stroke, as in prior art long stroke pumping units. As disclosed in this patent, an electric motor is used as the power source and during a downstroke, the winding drums work with the motor and thus a counter electromotive force is generated in the motor which can be employed to salvage much of the kinetic energy in the moving parts of the system. A simple limit switch is disclosed for reversing the electric motor; the patent further states that polish rod stroke and time delay may be modulated but discloses no structure or system for accomplishing such results. Another of my prior U.S. patents, U.S. Pat. No. 3,345,950 discloses a long stroke, deep well pumping unit either electrically or hydraulically powered and including a limit switch system alternately operated by the yoke suspending the polish rod and the counterweight to effect power source reversal.
Other long stroke, deep well pumping units that I have invented are disclosed in my prior U.S. Pat. Nos. 3,483,828; 3,538,777; 3,777,491; 3,792,836; and 3,986,564. FIGS. 4 and 5 of U.S. Pat. No. 3,777,491 disclose a hydraulically operated deep well pumping unit having a single, wide strap or belt as the operative connection between the polish rod and winding drum of the pump, which is somewhat similar to the lift belt of this invention.
However, the prior art does not disclose a simplified, uncomplicated long stroke, well pumping unit wherein a yo-yo drive as above discussed is employed with a flexible lift belt being the operative connection between the winding drum and the polish rod, power source reversal being positively associated with the winding drum rather than other components of the system, and stroke reversal being cushioned so as to reduce wear and tear on the unit and extend the life of the components of the unit. Of course, this unit is useful in wells of all depths, which particularly enhances the universality of application of the invention.
SUMMARY OF THE INVENTION
Therefore, it is a principal object of this invention to provide a yo-yo variety, long stroke, well pumping unit having a reversing mechanism positively associated with the winding drum of the pump unit and wherein stroke reversal is cushioned so as to ease the shock of stroke reversal on the components of the pumping unit.
It is another object of the invention to provide a yo-yo variety, long stroke, well pumping unit employing a flexible lift belt as the operative connection from the winding drum to the polish rod, the winding drum being structured and configured to reduce the effect of radius of the drum at the point of stroke reversal from a downstroke to an upstroke, thus to slow movement of the belt and ease the shock of stroke reversal.
It is yet another object of the invention to provide a yo-yo variety of long stroke, well pumping unit controlled by a reversing mechanism which provides a dwell or rest period, with the power source in an off position, between an upstroke and a downstroke, thus to ease the shock of stroke reversal.
It is a further object of the invention to provide a yo-yo variety driven, long stroke, well pumping unit having a counterweight arranged only for vertical movement and thus prevent side to side movement of the counterweight and significantly reduce lateral stresses in the system during operation of the pumping unit.
Still another object of the invention is to provide a yo-yo driven, long stroke, well pumping apparatus of greatly simplified construction which is low in cost of manufacture and easily maintained.
In general, the long stroke, well pumping unit of this invention includes a base platform, a tower on the platform, a rotatable winding drum on the platform with an electric drive, preferably, to impart rotation to the winding drum, a flexible lift belt connected at one end to the winding drum and at its other end to the upper end of the polish rod of a well pump, and a freely rotatable spool on top of the tower, over which the lift belt is trained. A counter weight is located on the lift belt, between the winding drum and the spool, and an idler pulley is located in the base of the tower, that portion of the lift belt between the counterweight and the winding drum being trained beneath the idler pulley or spool. The idler spool and upper spool arrangement generally confine counterweight movement during pumping operation to a vertical direction. A reversing mechanism or control is provided including, for example, a chain and sprocket transmission operable from the winding drum and rotating a contact for a limit switch. An end of the flexible lift belt is secured internally of the winding drum, that portion of the winding drum to either side of the flexible lift belt being curved so as to reduce the effective diameter of the drum during stroke reversal, from a downstroke to an upstroke. The structure and arrangement of both the reversing mechanism and the winding drum greatly reduce and cushion the shock of exchange from an upstroke to a downstroke and from a downstroke to an upstroke, respectively, during operation of the pump. The system is further cushioned in that at the termination of an upstroke, the power source is turned off by the reversing mechanism thus allowing the polish rod to gently fall under force of the rod string load, which is somewhat greater than that of the counterweight.
Further novel features and other objects of this invention will become apparent from the following detailed description, discussion and the appended claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred structural embodiment of this invention is disclosed in the accompanying drawings in which:
FIG. 1 is a partial, side elevation view of a well pumping unit of this invention;
FIG. 2 is a diagrammatic, top plan view of the base platform of the pumping unit shown in FIG. 1, with the tower structure and related components removed for purposes of clarity;
FIG. 3 is a section view of the winding drum of this invention;
FIGS. 4A, 4B and 4C are elevation views of the reversing mechanism, limit switch contact assembly which controls power source reversal of the pumping unit, the three views illustrating the three positions of the limit switch during pump operation; and
FIG. 5 is an exploded perspective view of the reversing mechanism control illustrated in FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings by reference character, and in particular to FIG. 1 thereof, a simplified, long stroke, well pumping unit is illustrated. A skid mounted base platform 10 supports a tower structure 12. A top platform 14 surmounts the tower structure 12. A rotatable winding drum 16 is located on base platform 10 and is driven by a drive belt arrangement from a power source 18 which,in a preferred embodiment of the invention, is a reversible, electric motor. An otherwise conventional well pump (not shown) includes a rod string and sucker rod therein, topped by a conventional polish rod 20. A flexible lift belt 22 is secured at one end to rotatable winding drum 16 and at its other end to a yoke assembly 24 from which the polish rod 20 is centrally suspended. Flexible lift belt 22 is reaved beneath an idler pulley or spool 26 on base platform 10, then upwardly through tower 12, to and over a spool 28, freely rotatably mounted atop the top platform 14, and then vertically downwardly to yoke assembly 24. A counterweight 30 is attached to or interposed within lift belt 22 and reciprocates generally vertically, with movement of lift belt 22, between the upper and lower ends of the tower structure 12. It can be seen that the location and arrangement of spool 28 with respect to idler pulley 26 generally confine movement of the counterweight 30 to a vertical direction. Thus, side to side movement of counterweight 30 during operation of the pump, which motion induces unnecessary lateral strains in the entire unit, is effectively reduced.
A fail safe mechanism 32 is located on top platform 14 and, in the event of failure by fracture of that portion of the lift belt generally between spool 28 and yoke 24 or of yoke 24, polish rod 20 or one of the components of the rod string, is operable to immediately grasp and clamp that portion of belt 22 between spool 28 and counterweight 30 and thus prevent counterweight 30 from falling. Fail safe mechanism 32 includes a lever platform 34, a counterweight 36, and a safety brake system 38. Upon failure of a component as just described, rod string and counterweight load on spool 28 are suddenly released whereupon counterweight 36 will rotate lever platform 34 in a counterclockwise direction, in the sense of FIG. 1, whereupon brake system 38 is mechanically forced to tightly clamp and engage belt 22 therewithin and prevent counterweight 30 from falling.
Commercially available conveyor belting may be employed of the material for lift belt 22. One available brand of conveyor belting that might be used is that sold under the trademark "UNILOK" as "PolyVinylok" conveyor belting. One particular material found to be useful is Unilok's PVK-350 Material, a belting that is 10/32 inches thick, 15 inches wide and has an ultimate tensile strength at rupture of 3500 pounds per inch. Similar materials sold under this same mark are available, up to 15/32 inches thick and having an ultimate tensile strength at rupture of up to 9000 pounds per inch. Belt widths may vary from 15 inches to 24 inches or more. The particular belting material chosen will, of course, depend on the design requirements of the particular well pumping unit.
With reference to FIG. 3, the novel winding drum of this invention is illustrated in cross section. An end of the flexible lift belt 22 is securely attached at 40 within winding drum 16. Belt 22 extends outwardly from the drum through a slot 42 defined by a pair of smaller but equal diameter cylinders 44, 44, on either side of slot 42. The surfaces of the cylinders 44 are smoothly blended into the larger diameter cylinder 46 forming the main body of winding drum 16. Flexible belt 22 has a dimension such that, at the end of the down stroke, with yoke 24 in a lowermost position, flexible belt 22 is completely paid out from the drum 16. At this point, winding drum 16 continues to rotate in the same direction as during the pay out of flexible belt 22, thus to initiate a winding up of flexible belt 22 upon drum 16 and thereby initiate a pump up stroke. Due to the structure of cylinders 44, it can be seen that during the terminal stage of a down stroke and the initial stage of an upstroke, the effective radius of the drum cylinder is reduced. Consequently, the velocity of movement of belt 22 is slowed with an increased mechanical advantage on the well side of the pump and the shock of transition from a downstroke to an upstroke, and the power source 18 coming under load, is significantly reduced.
Referring now to FIG. 2 of the drawings, the reversing mechanism of this invention is generally indicated by reference numeral 48. A chain and sprocket transmission 50 is operable from winding drum 16 through an idler shaft 52 and reduction gear box 54 to a second chain and sprocket transmission 56 and reversing control unit 58. Obviously, as an alternative, a single chain and sprocket connection from winding drum 16 to control unit 58 could be provided. The reversing control unit 58 is illustrated in detail in FIG. 5. A pair of segmented circular plates 60, 62, which may be identically dimensioned, are attached through their respective centers to a stud axle 64 which is rotated by chain and sprocket transmission 56, as shown. Plates 60, 62 are rotatably adjustable with respect to each other, by loosening stub axle nut 66, adjusting the plates so that their respective chords form an open notch 70 of predetermined dimensions, and then retightening nut 66 in place.
Referring now to FIG. 1 and FIGS. 4A, 4B and 4C, the yo-yo operation of the invention will now be described. For convenience of discussion, a cycle begins with counterweight 30 in its lowermost position, yoke 22 and polish rod 20 in their uppermost position and flexible belt 22 being wound as fully as it ever will be upon drum 16. In short, a downstroke is about to begin. At this stage in the cycle, the reversing control unit is positioned as illustrated in FIG. 4B with notch 70 embracing, but out of contact with, finger 72 of a three position, spring loaded limit switch 74. In this embodiment, the power source is a reversible electric motor. Limit switch 74 may be of any conventional, commercially available type, such as a Cutler Hammer E50 SN Limit Switch. Of course, limit switch 74 is suitably, conventionally connected to power source 18. As shown in FIG. 4B, finger 72 of limit switch 74 is in a vertical, neutral position; thus, the electric motor comprising the power source 18 is in a power off position. Counterweight 30 has previously been weighted so that polish rod load exceeds the load generated by the counterweight. Thus, yoke 24 and polish rod 20 will begin to descend, thus initiating a downstroke. As this occurs, drum 16 is forced to rotate in a counterclockwise direction, in the sense of FIG. 1, as flexible belt 22 is paid out therefrom. Simultaneously, plates 60, 62 of reversing control unit 58 are caused to rotate counterclockwise because of the chain and sprocket transmission connection to winding drum 16. The reversing control unit 58 then assumes the position illustrated in FIG. 4A, with limit switch finger 72 moved to the right which turns the power source motor to one of its on positions. Finger 72 includes a freely rotatable roller 76 at the free end thereof which first contacts a chord 68 of plate 62 whereupon the upper part of finger 72 is forced to rotate to the right and turn the switch 74 to an on position as roller 76 approaches the periphery of plate 62. Switch 74 is maintained in a first on position as the down stroke continues and plates 62, 60 continue their counterclockwise rotation, with roller 76 riding about the periphery of plates 60, 62.
It is important to note that as the downstroke continues and with power source motor 18 turned on, as just described, the winding drum 16 works with the motor and thus a counter electromotive force is generated in the power source motor 18 which may be used to salvage much of the kinetic energy in the moving parts of the system; in short, the motor acts as a generator as the down stroke continues, in a manner well known in the electrical art.
As the downstroke nears an end, plates 60, 62 will have rotated about 180 degrees from the initial position shown in FIG. 4B. At this point, all of the flexible belt 22 will be unwound from drum 16 but the drum will continue to rotate in a counterclockwise fashion thus initiating an upstroke as flexible belt 22 is rewound upon drum 16. Since the limit switch remains in the position illustrated in FIG. 4A, the power source 18 then runs under load and the counterweight travels from the position indicated in phantom lines at the top of the tower to the position shown in the bottom of the tower in solid lines. Thus, a full cycle of a down stroke and an up stroke is accomplished without need for reversal of rotation of winding drum 16 and consequently of the motor 18 as well. At the completion of the upstroke, plates 60, 62 will have rotated through about 360 degrees and again assume the position illustrated in FIG. 4B, whereupon the power source motor 18 will be in a power off position. The amount of time alloted to this power on position is predetermined by adjustment of plates 60, 62 as above described to set the dimensions of notch 70. Obviously, the smaller the notch, the longer the power on period will be and vice versa. Accordingly, the stroke distance of the unit may be adjusted by relative adjustment of the plates 60, 62 as aforesaid. Due to the polish rod load being in excess of the load generated by counterweight, the rod string again falls, to thereby initiate a second downstroke. At this point, flexible belt 22 will begin to unwind from drum 16 and drum 16 will now rotate in a clockwise direction. Consequently, plates 60, 62 of reversing control unit 58 will also be caused to rotate in a clockwise direction, to assume the position illustrated in FIG. 4C. At this point, switch 74 has been moved to a second, power on position. Additionally, the motor again acts as a generator, as above described. As the downstroke is terminated, drum 16 continues to rotate in a clockwise direction thus rewinding flexible belt 22 thereon without reversal of the direction of rotation of winding drum 16 and with power source motor 18 under load to effect a second upstroke. At the termination of this up stroke, the control unit again assumes the attitude illustrated in FIG. 4B and the first of the two cycles just described is initiated again. Thus, it is seen that only one drum and motor reversal is required for two strokes or one cycle of pump operation.
In one embodiment of the invention, a pumping unit is dimensioned to provide a 25 foot stroke in polish rod 20. This is economically practical because commonly available, off-the-shelf components may be interfaced with the unit. For example, a standard long stroke pump is thirty feet long and has a plunger 5 feet in length. Additionally, standard polish rods and standard rods making up the rod string are compatible with a pump having a 25 foot stroke.
A comparison of the production figures of a standard walking beam pump unit with a long stroke pumping unit herein disclosed yields the following interesting results. In pumping a well about one mile deep, a standard walking beam unit with a 10-foot stroke and operating at 8 strokes per minute will produce a net lift per minute of 40 feet, when a rod stretch of 5 feet on the lift stroke is taken into account. Conversely, use of a pumping unit as above disclosed, with a 25-foot stroke and operating only at 4 strokes per minute, yields a net lift per minute of 80 feet, again taking the 5 feet of rod stretch on the lift stroke into account. Thus, in this comparison, the present invention is 100 percent more efficient.
Equally importantly, the long, slower, half speed stroke just described reduces the number of cycles required per minute and extends rod and tubing life by distributing wear over a greater area. The following table sets forth numbers of strokes and cycles per selected units of time dependent upon the number of strokes or cycles per minute selected in the design of a particular unit.
__________________________________________________________________________STROKE AND CYCLE INFORMATION ON DEEP WELL PUMPING UNITSTROKES CYCLES OR REVERSALSMin. Hour Day Month Year Min. Hour Day Month Year__________________________________________________________________________1 60 1440 43,200 525,600 2 120 2880 86,400 1,051,2002 120 2880 86,400 1,051,200 4 240 5760 172,800 2,102,4003 180 4320 129,600 1,576,800 6 360 8640 259,200 3,153,6004 240 5760 172,800 2,102,400 8 480 11520 354,600 4,204,8005 300 7200 216,000 2,628,000 10 600 14400 432,000 5,256,0006 360 8640 259,200 3,153,600 12 720 17280 518,400 6,307,200__________________________________________________________________________
It can be readily appreciated from the table that, over a years' time when the count of cycles numbers in the millions that a long stroke unit designed in accordance with the principals of this invention will have an operating life far longer than that of prior art pumping units, such as a walking beam pump operating at twice the speed of the pumping unit of this invention, or greater.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiment is therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. | A yo-yo variety reversing mechanism for long stroke, well pumping units, which employ a lift belt as the operative link between a winding drum and the polish rod of the well pump. Shock experienced between transfer from an upstroke to a downstroke is cushioned by the reversing mechanism or control which provides a power source off dwell period during the aforesaid stroke exchange. Further cushioning is provided by a novel winding drum for the lift belt which decreases the effective radius of the drum at the point of exchange from a downstroke to an upstroke to thus slow movement of the belt and cushion the shock of exchange from a downstroke to an upstroke. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to alunite-type compounds and more particularly it relates to a process for making alunite and a high purity product, e.g., natroalunite resulting therefrom.
The occurrence and geology of the mineral alunite in many parts of the world is widely recognized and well documented. However, such natural deposits contain many impurities such as quartz, kaolin, iron oxides and other minerals which are difficult and expensive to remove. Further, natroalunite, which has sodium in the place of potassium in the chemical formula, is often mixed with alunite and is not found in the pure form in deposits. Ammonium alunite has ammonium in place of potassium. There are no reports of its occurrence in nature.
U.S. Pat. No. 3,436,176 discloses a process for producing high purity alumina from aluminum-bearing acidic, sulfate solutions. According to the patent, the feed solution may be considered as taken from a cyclic backing system of the waste dump of a copper mine, and a sodium or ammonium salt is added to such feed solution. With the salt added, 85% of the aluminum values present in the solution precipitates as sodium or ammonium alunite which contains 35 to 45% aluminum oxide, less than 3% iron, and less than 5% sodium or ammonium ions. Thereafter, the sodium or ammonium alunite is calcined and digested to produce alumina.
However, there is still a great need for a process to produce a high purity alunite, e.g., natroalunite. The present invention provides such a process and produces a high purity alunite.
SUMMARY OF THE INVENTION
Disclosed is a method for preparing high purity alunite. In the method, a material selected from the group consisting of sodium sulfate, sodium bisulfate, ammonium sulfate, ammonium bisulfate, potassium sulfate and potassium bisulfate is provided and reacted with a source of aluminum hydroxide in a liquid. The reaction is carried out under acidic conditions, and alunite is recovered after separating and drying.
An object of the invention is to provide a method for producing high purity alunite.
Another object of the invention is to provide a method for producing high purity natroalunite.
Yet another object of the invention is to provide a method for producing high purity ammonium alunite.
Yet another object of the invention is to provide a method for producing high purity potassium alunite.
Still a further object of the invention is to produce high purity natroalunite.
Still a further object of the invention is to produce high purity ammonium alunite.
Still a further object of the invention is to produce high purity potassium alunite.
These and other objects will become apparent from the drawings, specification and claims appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an SEM picture of the sodium alunite (natroalunite) product.
FIG. 2 is an X-ray diffraction pattern of ammonium alunite.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a process for producing high purity natroalunite, for example. The alunite is produced in accordance with the following reaction:
2MHSO.sub.4 +3Al(OH).sub.3 →MAl.sub.3 (SO.sub.4).sub.2 (OH).sub.6 +2H.sub.2 O+MOH
where M is selected from sodium, potassium and ammonium. Thus, the sulfate can be selected from sodium sulfate or sodium bisulfate, ammonium sulfate or ammonium bisulfate, and potassium sulfate or potassium bisulfate. Preferably, the weight ratio sulfate to hydroxide is slightly in excess of the stoichiometric amount required for the reaction. That is, preferably, the alkaline sulfate is in excess of the stoichiometric amount by 10 to 100 weight percent. The aluminum hydroxide preferred is solid crystalline aluminum hydroxide, e.g., aluminum trihydroxide such as gibbsite available from the Bayer process, 95 wt., preferably 99 wt.% purity. Preferably, the aluminum hydroxide has a particle size in the range of 1 to 200 μm with a typical size being in the range of 10 to 100 μm.
For purposes of effecting the reaction, the sulfate or bisulfate is provided in an aqueous solution. Preferably, the concentration of sulfate or bisulfate in the solution is in the range of 0.2 to 6 molar, typically in the range of 0.5 to 4 molar with a suitable concentration being 1 to 2 molar.
Further, for effecting the reaction, the pH of the aqueous solution is maintained in the range of 1 to 6, preferably 1.5 to 5 and typically 2 to 4. The pH can be adjusted by adding sulfuric acid, for example.
In addition, the reaction can be carried out at a temperature of at least 80° C, preferably more than 100° C. Normally, a temperature of over 250° C. is not required, but a higher temperature may be used. Preferably, the reaction is carried out at a temperature in the range of 120° to 200° C.
The reactants are kept in this temperature range for a sufficient time for the reaction to occur. Normally, this time is in the range of about 20 minutes to about 10 hours with longer times not being detrimental. Typical reaction times are in the range of 1/2 to 8 hours.
The reaction may be carried out under autogeneous pressure in a closed or fluid-tight vessel. The product produced in accordance with the invention has a purity of at least 90 wt.%, and typically the purity is greater than 95%. Iron oxide and silica are less than 0.5 wt.% and typically less than 0.2 wt.% with preferred levels being less than 0.1 wt.%. The highest level of material incorporated in the alunite is aluminum hydroxide which can be as high as 10 wt.% but is generally less than 5 wt.% and typically less than 1 wt.%. Thus, it will be seen that a unique product results from the combination of alunite and aluminum hydroxide dispersed therethrough, and such is contemplated within the purview of the invention. Thus, the product can contain greater than 90 wt.% alunite, the remainder aluminum hydroxide, incidental elements and impurities. The aluminum hydroxide used in the reaction is the source of most impurities, and thus, the higher level of impurity in the aluminum hydroxide, the higher level of impurities in the product.
When natroalunite is produced, the product is white, free flowing and crystalline after separation, washing and drying. If it is desired to improve the level of whiteness, then a bleaching agent can be used. The bleaching agent can be added with the reactants and can range from 0.1 to 2.5 wt.%, typically 0.7 to 17 wt.%, based on the weight of aluminum hydroxide used. Such agents can include sodium hypochlorite, sodium persulfate and hydrogen peroxide.
After the reaction, the product can be separated from the aqueous solution by filtration or centrifugation. Thereafter, it can be washed in deionized water and then dried to produce the free-flowing powder.
When sodium or natroalunite was produced in accordance with the invention, chemical analysis showed this material corresponded to the formula NaAl 3 (SO 4 ) 2 (OH) 6 . Also, X-ray diffraction identification showed that this material was pure natroalunite, i.e., identical to the diffraction pattern on card number 14-130, published by The Joint Committee on Powder Diffraction (JCPDS), International Center for Diffraction Data, Swarthmore, PA 19081.
The particle size of the alunite product is generally about the size of the Al(OH) material used in the reaction. FIG. 1 is an SEM picture of the sodium alunite product.
The natroalunite and potassium alunite product is thermally stable to 500° C. The product is useful as a filler in plastic and rubber products and is suitable for use in the production of artificial or cultured marble.
EXAMPLE 1
Natroalunite was prepared as follows: An 18 liter total volume stainless steel autoclave was filled with 12 liters of deionized water. 1350 grams of sodium bisulphate were added to the water and dissolved by operating the stirrer. 750 grams of crystalline aluminum hydroxide were added and the autoclave closed. The autoclave was then heated to 175° C. while maintaining vigorous agitation and held at that temperature for a period of 4 hours. The autoclave was then cooled to room temperature and emptied. The solid product was filtered, washed with hot deionized water and dried overnight at 110° C. Chemical and X-ray diffraction analysis of the product showed it to be pure natroalunite.
EXAMPLE 2
Ammonium alunite was prepared as follows: 1350 grams of ammonium bisulphate were dissolved in 12 liters of deionized water in the same autoclave system used in Example 1. 900 grams of crystalline aluminum hydroxide were added and the autoclave was closed and heated to 175° C. with vigorous agitation. The autoclave was held at this temperature for 4 hours and then cooled to room temperature. The product from the autoclave was filtered, washed and dried as before. Chemical analysis of the product corresponded closely to the formula NH 4 Al 3 (SO 4 ) 2 (OH) 6 . The X-ray diffraction pattern of the product is shown in FIG. 2. The pattern was interpreted as belonging to the alunite family though it differs from that of natroalunite.
EXAMPLE 3
This example was performed to improve the whiteness of natroalunite by addition of a bleaching agent. Experiments described in Example 1 were repeated using Bayer Process alumina hydrate having a whiteness index of 57 as the aluminum hydroxide source. The whiteness measurement was carried out using a colorimeter (Pacific Scientific Colorgard System 105) instrument. The first batch was obtained without using any bleaching agent. The whiteness index of the resulting natroalunite product was measured to be 83. In the preparation of the second batch, 100 ml of 30% hydrogen peroxide solution were added to the reaction mixture in the autoclave before closing the autoclave. The resulting product had an improved whiteness index of 94 measured in the same instrument.
While the invention has been described in terms of preferred embodiments, the claims appended hereto are intended to encompass other embodiments which fall within the spirit of the invention. | Disclosed is a method for preparing high purity alunite. In the method, a material selected from the group consisting of sodium sulfate, sodium bisulfate, ammonium sulfate, ammonium bisulfate, potassium sulfate and potassium bisulfate is provided and reacted with a source of aluminum hydroxide in a liquid. The reaction is carried out under acidic conditions, and alunite is recovered after separating, washing and drying. | 2 |
FIELD OF THE INVENTION
[0001] This invention is directed generally to turbine blades, and more particularly to hollow turbine blades having internal cooling channels for passing cooling fluids, such as air, to cool the blades.
BACKGROUND
[0002] Typically, gas turbine engines include a compressor for compressing air, a combustor for mixing the compressed air with fuel and igniting the mixture, and a turbine blade assembly for producing power. Combustors often operate at high temperatures that may exceed 2,500 degrees Fahrenheit. Typical turbine combustor configurations expose turbine blade assemblies to these high temperatures. As a result, turbine blades must be made of materials capable of withstanding such high temperatures. In addition, turbine blades often contain cooling systems for prolonging the life of the blades and reducing the likelihood of failure as a result of excessive temperatures.
[0003] Typically, turbine blades, as shown in FIG. 1 , are formed from a root portion and a platform at one end and an elongated portion forming a blade that extends outwardly from the platform. The blade is ordinarily composed of a tip opposite the root section, a leading edge, and a trailing edge. The inner aspects of most turbine blades typically contain an intricate maze of cooling channels forming a cooling system. The cooling channels in the blades receive air from the compressor of the turbine engine and pass the air through the blade. The cooling channels often include multiple flow paths that are designed to maintain all aspects of the turbine blade at a relatively uniform temperature. However, centrifugal forces and air flow at boundary layers often prevent some areas of the turbine blade from being adequately cooled, which results in the formation of localized hot spots. Localized hot spots, depending on their location, can reduce the useful life of a turbine blade and can damage a turbine blade to an extent necessitating replacement of the blade.
[0004] Conventional turbine blades may have one or more root turns, as shown in FIG. 2 , which are located proximate to the root. Conventional root turns are typically curved elements of the flow path that change the direction of cooling fluid flow about 180 degrees in a serpentine formation in the root. While a conventional root turn successfully redirects cooling fluid flow from flowing spanwise towards a root to flowing spanwise towards the blade tip, a conventional root turn causes the cooling fluids flowing through the conventional root turn to undergo a significant pressure loss. Such a pressure loss often causes undesirable hot spots to develop in portions of the turbine blades. Thus, an internal cooling system having reduced pressure loss cooling fluid turns is needed.
SUMMARY OF THE INVENTION
[0005] This invention relates to a turbine blade capable of being used in turbine engines and having a turbine blade cooling system for dissipating heat from the turbine blade. The turbine blade may be a generally elongated blade having a leading edge, a trailing edge, a tip at a first end, a root coupled to the blade at an end generally opposite the first end for supporting the blade and for coupling the blade to a disc, at least one cavity forming a cooling system in the blade, and at least one outer wall defining the cavity forming at least a portion of the cooling system. The cooling system includes at least one serpentine cooling channel for directing cooling fluids through internal aspects of the turbine blade.
[0006] The serpentine cooling channel may be formed from a first leg extending generally from the root towards the blade tip, a second leg in communication with the first leg and extending towards the root, and a third leg in communication with the second leg through a root turn and extending generally towards the tip. The root turn is configured to reduce the pressure loss associated with conventional root turns. For instance, the root turn may be formed from a first rib extending from the root spanwise towards the tip and separating the first and second legs, a second rib extending from the root towards the tip and forming a portion of the third leg, and a third rib extending between the first and second ribs. In at least one embodiment, the third leg may be substantially straight. The third rib may be positioned generally orthogonal to the first and third ribs. In other embodiments, the third rib may be positioned nonorthogonally to the first or second rib, or both. In at least one embodiment, the first, second, and third ribs form a generally rectangular root turn. The root turn may have different sizes, but in at least one embodiment, the root turn has a spanwise length that is at least as long as about half of a length of the second leg of the serpentine channel.
[0007] The turbine blade cooling system may also include one or more refresh holes extending between the first leg and the second leg and positioned proximate to the root turn to direct cooling fluid into the upstream portion of the root turn. The refresh hole may have a bell shaped inlet and a straight outlet. The refresh hole may also be positioned relative to a direction in which the cooling fluid is flowing through the second leg of the serpentine cooling channel such that the cooling fluid expelled from the refresh hole is directed into the root turn in the same general direction as the cooling fluid flowing through the root turn. For example, the refresh hole may be positioned between about 15 degrees and about 75 degrees relative to the direction of flow of the cooling fluid through the second leg, and, in at least one embodiment, may be positioned about 45 degrees relative to the direction of fluid flow.
[0008] The root turn advantageously reduces the pressure loss coefficient associated with conventional root turns. In fact, the root turn of the instant invention reduces a pressure loss coefficient to about 0.6 in at least one embodiment, from about 2.0 experienced in conventional designs.
[0009] Another advantage of the invention is the refresh holes reduce the total flow needed to cool a portion of a turbine blade because at least a portion of the cooling fluids do not pass through the first and second legs of the serpentine cooling channel; rather, some of the cooling fluids pass through the refresh hole and directly into the root turn. Thus, the fluid that passes through the refresh hole does not pick up heat from the first and second legs of the serpentine cooling channel. Therefore, cooling fluids are capable of being passed through the root turn and the third leg in reduced amounts, yet still accomplish the same amount of cooling.
[0010] Yet another advantage of the invention is that the root turn is easier to manufacture than many conventional root turns.
[0011] Still another advantage of the invention is that the angle at which cooling fluids are added to the root turn enables a greater amount of cooling fluid to be added to the root turn than in conventional root turns.
[0012] These and other embodiments are described in more detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings, which are incorporated in and form a part of the specification, illustrate embodiments of the presently disclosed invention and, together with the description, disclose the principles of the invention.
[0014] FIG. 1 is a perspective view of a conventional turbine blade.
[0015] FIG. 2 is a cross-sectional view of the conventional turbine blade shown in FIG. 1 taken along section line 2 - 2 .
[0016] FIG. 3 is a perspective view of a turbine blade having features according to the instant invention.
[0017] FIG. 4 is cross-sectional view of the turbine blade shown in FIG. 3 taken along section line 4 - 4 .
[0018] FIG. 5 is a detail of the root turn shown in FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
[0019] As shown in FIGS. 3-5 , this invention is directed to a turbine blade cooling system 10 for turbine blades 12 used in turbine engines. In particular, turbine blade cooling system 10 is directed to a cooling system 10 located in a cavity 14 , as shown in FIG. 4 , positioned between outer walls 22 . Outer walls 22 form a housing 24 of the turbine blade 12 , as shown in FIG. 3 . The turbine blade 12 may be formed from a root 16 having a platform 18 and a generally elongated blade 20 coupled to the root 16 at the platform 18 . The turbine blade may also include a tip 36 generally opposite the root 16 and the platform 18 . Blade 20 may have an outer wall 22 adapted for use, for example, in a first stage of an axial flow turbine engine. Outer wall 22 may have a generally concave shaped portion forming pressure side 26 and may have a generally convex shaped portion forming suction side 28 .
[0020] The cavity 14 , as shown in FIG. 4 , may be positioned in inner aspects of the blade 20 for directing one or more gases, which may include air received from a compressor (not shown), through the blade 20 and out one or more orifices 34 in the blade 20 . As shown in FIG. 3 , the orifices 34 may be positioned in a leading edge 38 , a trailing edge 40 , the pressure side 26 , and the suction side 28 to provide film cooling. The orifices 34 provide a pathway from the cavity 14 through the outer wall 22 .
[0021] As shown in FIG. 4 , the cavity 14 forming the cooling system 10 may have at least one serpentine cooling channel 42 . The exemplary turbine blade shown in FIG. 4 includes two serpentine cooling channels 42 ; however, for ease in discussion, only one of the serpentine cooling channels is described below. The serpentine cooling channel 42 shown in FIG. 4 is a triple pass cooling channel 42 ; however, the invention is not limited to this configuration. Instead, the serpentine cooling channel 42 may be formed from cooling channels having other number of passes. The serpentine cooling channel 42 may be formed from a first leg 44 extending spanwise generally from the root 16 towards the tip 36 , a second leg 46 in communication with the first leg 44 and extending towards the root 16 from an end of the first leg 44 closest the tip 36 , and a third leg 48 in communication with the second leg 46 via a root turn 50 and extending generally towards the tip 36 . The first and second legs 44 and 46 may be separated by one or more ribs 52 . Likewise, second and third legs 46 and 48 may be separated by one or more ribs 54 .
[0022] The root turn 50 may be formed from the rib 52 extending spanwise from the root 16 towards the tip 36 and separating the first and second legs 44 and 46 , a rib 56 extending spanwise from the root 16 towards the tip 36 and forming a portion of the third leg 48 , and a rib 58 extending between the rib 52 and the rib 56 . In at least one embodiment, the rib 56 may be substantially straight, as shown in FIG. 4 . The rib 58 may, in at least one embodiment, be positioned generally orthogonal to ribs 52 and 56 . In another embodiment, the rib 58 may be positioned nonorthogonally relative to the ribs 52 and 56 . The root turn 50 , as extending spanwise from the rib 58 to the rib 54 , may have a spanwise length that is at least as long as about half of a spanwise length of the second leg 46 of the serpentine cooling channel 42 . In at least one embodiment, a mouth 59 of the second leg 46 has a cross-sectional area that is greater than or equal to the cross-sectional area of the third leg 48 proximate to the root turn 50 . This relationship establishes proper flow through the root turn 50 . If the cross-sectional area at mouth 59 is less than the cross-sectional area of the third leg 48 , then the cooling fluid flowing through the mouth 59 undergoes a sudden expansion that causes flow separation, recirculation, and pressure loss. Further, the flow of cooling fluids may not be able to fill the third leg 48 downstream of the root turn 50 when the cross-sectional area at mouth 59 is less than the cross-sectional area of the third leg 48 .
[0023] The turbine blade cooling system 10 may also include one or more refresh holes 60 , as shown in FIGS. 4 and 5 . The refresh hole 60 may be positioned in the rib 52 proximate to an end of the rib 54 for injecting cooling fluid into the root turn 50 on an upstream side 62 of the root turn 50 . The refresh hole 60 may be aligned such that a centerline 64 of the refresh hole is at an angle α with a value between about 15 degrees and about 75 degrees relative to the flow of cooling fluids through the second leg 46 . In at least one embodiment, the angle α may be about 45 degrees. The refresh hole 60 may have a bell mouth inlet section 68 and a straight exit region 70 or a convergent section for pushing the flow. The mouth section 68 may be positioned to draw cooling fluids from the cavity 14 before the cooling fluid enters the serpentine cooling channel 42 , which provides cooling fluids to the root turn 50 that have yet to pick up heat from the outer walls 22 of the turbine blade 20 .
[0024] By including the refresh hole 60 proximate to the mouth 59 on the upstream portion of the root turn 50 , the cooling fluids passing through the refresh hole 60 influence the cooling fluids flowing through the second leg 46 and into the root turn 50 . In fact, the refresh hole 60 in the root turn 50 reduces the pressure loss compared to conventional designs. The refresh hole 60 enables cooling fluids to bypass the first and second legs 44 and 46 and therefore enter the root turn 16 at a lower temperature than had the cooling fluids flowed through the first and second legs 44 and 46 .
[0025] In operation, cooling fluids flow into the cooling cavity 14 through the root 16 . A portion of the cooling fluids enter the first leg 44 , pass into the second leg 46 , and pass into the root turn 50 . Simultaneously, cooling fluids pass through the refresh hole 60 and mix with the cooling fluids flowing from the second leg 46 . The elimination of the conventional root turn geometry shown in FIG. 2 eliminates the constraint on the cooling fluid flow through a serpentine cooling channel, which allows the cooling fluid to form a free stream tube in the root turn 50 . The embodiment shown in FIG. 4 has been shown to reduce pressure loss coefficient from 2.0 to about 0.6 as compared with a conventional root turn shown in FIG. 2 .
[0026] The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of this invention. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of this invention. | A turbine blade for a turbine engine having a cooling system with at least one serpentine cooling channel in internal aspects of the turbine blade. The serpentine cooling channel includes at least one root turn proximate to a root of the turbine blade. The root turn may have a generally rectangular shape and may account for reduced pressure losses relative to conventional curved root turns. One or more refresh holes may be positioned in a rib proximate to the root turn to provide the root turn with cooling fluids that have bypassed the first and second legs of the serpentine cooling channel. | 5 |
TECHNICAL FIELD
[0001] This invention generally relates to telemetry systems of a vehicle, and more particularly, this invention relates to wireless telemetry systems and methods for vehicle brake systems.
BACKGROUND
[0002] Brake systems for road vehicles are designed to operate at a high level of performance and reliability. Accurate information regarding operating conditions of the brake systems components during use is therefore desired to optimize and maintain brake system performance and to advise the vehicle operator of brake system service needs. However, reliably obtaining data from wheel-borne brake system components such as calipers, brake linings (e.g., brake pads), rotors and the like requires routing wire harnesses to these components at each wheel. Owing to the movement of the wheel during vehicle use and the potentially harsh environment at each wheel, providing wiring to each wheel to monitor brake system components adds manufacturing cost and complexity and introduces potential reliability issues.
[0003] Optimization of vehicle and brake system operating conditions also requires accurate and timely system data. For example, to control brake component cooling requires real time brake system temperature information. Methods have been proposed to predict brake system temperatures based upon vehicle load; speed, deceleration rate and ambient temperatures. As will be appreciated, predictive algorithms are not actual brake component data, and thus have inherent inaccuracy. Additional algorithms have been proposed to predict brake system condition and maintenance needs as a result of use. These algorithms may provide acceptable indications, but they are not a substitute for actual data.
[0004] Accordingly, it is desirable to provide methods and systems to obtain and communicate brake system operating data, including brake system operating data from wheel-borne brake system components, without the addition of wiring harnesses. Furthermore, other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background.
SUMMARY
[0005] Brake system telemetry systems and methods utilize wireless communication technology to communicate brake system data to one or more vehicle electronic control modules. In one embodiment, a wireless transmitter is provided and is operably disposed with the brake system components located at each wheel of the vehicle. The wireless transmitter is coupled to receive data from various components of the brake system at the respective wheel and to wirelessly communicate the data to one or more electronic control units within the vehicle.
[0006] In another embodiment, a wireless transmitter is provided in connection with a brake system component sensors at each wheel of the vehicle. The wireless transmitter may part of a first module that measures and communicates brake system data. A second module, in response to the communicated brake system data, takes an action in connection with the operation of the vehicle or provides an indication of brake system condition to a user of the vehicle.
[0007] In another aspect of the herein described embodiments, the sensors and wireless transmitter at the wheel locations are characterized by an absence of wiring connections or harnesses to the sensors and/or wireless transmitter.
[0008] In still another embodiment, a method of monitoring brake system operation includes obtaining one or more brake system data, and wireless communicating the brake system operating data to a control module within the vehicle.
DESCRIPTION OF THE DRAWINGS
[0009] The exemplary embodiments will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:
[0010] FIG. 1 is a graphic depiction of a vehicle that includes a brake telemetry system in accordance with various embodiments;
[0011] FIG. 2 is a functional block diagram of a vehicle that includes a brake telemetry system in accordance with various embodiments; and
[0012] FIG. 3 is a schematic diagram of brake system components in accordance with various embodiments.
DETAILED DESCRIPTION
[0013] The following detailed description is merely exemplary in nature and is not intended to limit the application and uses. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. As used herein, the term system or module may refer to any combination or collection of mechanical and electrical hardware, software, firmware, electronic control component, processing logic, and/or processor device, individually or in any combination, including without limitation: application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group), memory that executes one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described functionality.
[0014] Embodiments of the invention may be described herein in terms of functional and/or logical block components and various processing steps. It should be appreciated that such block components may be realized by any number, combination or collection of mechanical and electrical hardware, software, and/or firmware components configured to perform the specified functions. For example, an embodiment of the invention may employ various combinations of mechanical components, e.g., brake calipers, brake pads, brake lines and brake rotors; and electrical components, e.g., integrated circuit components, memory elements, digital signal processing elements, logic elements, look-up tables, or the like, which may carry out a variety of functions under the control of one or more microprocessors or other control devices. In addition, those skilled in the art will appreciate that embodiments of the present invention may be practiced in conjunction with any number of mechanical and/or electronic systems, and that the vehicle systems described herein are merely exemplary embodiment of the invention.
[0015] For the sake of brevity, conventional components and techniques and other functional aspects of the systems (and the individual operating components of the systems) may not be described in detail herein. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent example functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in an embodiment of the invention.
[0016] Referring now to FIGS. 1 and 2 , a vehicle 10 is shown to include a first module including a vehicle brake telemetry system 12 and a second module including at least one electronic vehicle controller 14 . For exemplary purposes, the disclosure will be discussed in the context of the brake telemetry system 12 reporting data from wheel locations of the vehicle 10 . The skilled person will recognize that suitable components such as brake calipers, pads, rotors and lines may be disposed at each wheel of the vehicle 10 , or that a centralized brake system may be envisioned wherein operative components are coupled to one or more driveline components in lieu of or in addition to components being disposed at the wheels. Additionally, it will be further appreciated that the herein described brake system components are joined to conventional vehicle operator actuation components, automated actuation components and various combinations thereof to affect on command brake application.
[0017] The brake telemetry system 12 couples a plurality of sensors to a wireless transmitter 16 . The sensors and wireless transmitter 16 may be self-powered or self-powering, and operable absent any wire harness or wired connection thereto from other components or systems on or within the vehicle. As shown in FIG. 2 , a plurality of data may be sensed, with four (4) data types shown for exemplary purposes. Exemplary data may include sensor provided brake rotor temperature 18 , brake pad temperature 20 , brake pressure 22 and pad wear 24 . It will be appreciated that virtually any additional brake system operating parameter that may be observed, measured or sensed and reported as an electronic or digital value may be incorporated into the brake telemetry system 12 .
[0018] Transmitter 16 is configured to communicate data via wireless transmission to a receiver 26 associated with vehicle controller 14 . As depicted, the receiver 26 is a separate component within the vehicle controller 14 . Alternatively, receiver 26 may be a separate component disposed within the vehicle 10 and communicatively linked to the electronic controller 14 and/or to other controllers within the vehicle 10 via, e.g., a communication bus. Vehicle controller 14 may additionally be communicatively linked to other controllers within the vehicle 10 and/or to communicate with or to control various systems within the vehicle 10 , e.g., by a communication bus. As depicted in FIG. 2 , the receiver 26 may communicate received data to a braking system controller 28 , a body controller 30 , a powertrain controller 32 , a Driver Information Center (DIC) 34 or any other controller or module within the vehicle 10 that may benefit from or use the communicated data.
[0019] Transmitter 16 and receiver 26 may operate utilizing any suitable wireless communication protocol, and communication protocols for short range data communication within a vehicle are known. The transmitter 16 may be configured to prioritize data communication based upon data type. Data that may change rapidly with vehicle use may be reported with a first frequency, while data that changes slowly with vehicle use may be reported with a second frequency. For example, data relating to brake component temperature may be reported with a high frequency, while data relating to brake pad wear may be reported with a low frequency. Alternatively, an alarm or exception based protocol may be employed.
[0020] The schematic diagram of FIG. 3 illustrates the mechanical components of a vehicle brake system that may be disposed at each wheel of the vehicle, or may be coupled to a driveline component, such as a transmission, transfer case or differential output shaft. The brake system may include a brake rotor 36 , a brake caliper 38 , brake pads 40 , all of which may be of conventional construction. The brake caliper 38 may be coupled conventionally via a hydraulic line to an operator or automated control to affect commanded brake action.
[0021] Transmitter 16 may be physically associated with the brake caliper 38 or other brake system component. Brake rotor 36 /brake pads 40 may incorporate temperature and/or wear sensor 42 , which may be an embedded wire loop or loops and/or thermo-couple type sensors within the brake pads 42 . Other sensor technologies may be used. For example, an infra-red sensor may be used to measure brake rotor 36 or brake pad 40 temperature. As a further alternative, a printed sensor (not depicted) with multiple circuits may be embedded into the brake pads 40 to measure brake pad 40 temperature as a change in resistance in the circuit with change in temperature. Furthermore, there could be circuit loops at various depths in the brake pads 40 so that as the brake pads 40 wear, loops would wear through, opening that circuit, and denoting that the brake pad had worn through to that point.
[0022] The sensors and wireless transmitter 16 may include a battery power source. Alternatively, the sensors and wireless transmitter 16 may be self-powering by incorporating piezoelectric circuits that generate power from temperature changes and/or the motion and vibration during use of the vehicle 10 . Other structures and methods to power the transmitter 16 without a direct wire connection power supply may be used.
[0023] Benefits from brake telemetry systems in accordance with herein described embodiments are readily apparent. Immediate, accurate information relating to the status and operation of brake system components can be known without the cost, complexity and reliability concerns of providing a wired connection to the wheel-borne brake system components. Service requirements, such as renewing brake friction materials, e.g., brake pads and brake rotors, can be readily and accurately determined. Conditions suggesting compromised braking performance are readily identified. In each case, timely and accurate information regarding the condition of the brake system can be made available to the vehicle operator through any number of means, including a Driver Information Center within the vehicle, and operation of the vehicle itself can be adjusted via various vehicle controllers.
[0024] Additional benefits and advantages can be derived from use of a brake telemetry system in accordance with the herein described embodiments in connection with the overall operation of the vehicle braking system and associated vehicle systems. It is known to incorporate air ducts within a vehicle to direct cooling air to the brake system components. Such air ducts introduce aerodynamic drag to the vehicle, which reduces vehicle economy or limits maximum vehicle performance. Accurate and timely information of brake system component temperatures allows active management of the air ducts via a body controller or brake system controller or combinations thereof, opening and closing the ducts as required to provide brake component cooling only when required.
[0025] Yet another advantage arises with the ability to diagnose brake system operation especially during autonomous vehicle operation and/or autonomous brake application events. Accurate and timely brake performance data provides necessary feedback to autonomous control systems ensuring correct brake system operation.
[0026] While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing the exemplary embodiment or exemplary embodiments. It should be understood that various changes can be made in the function and arrangement of elements without departing from the scope of the disclosure as set forth in the appended claims and the legal equivalents thereof. | Brake system telemetry systems and methods utilize wireless communication technology to communicate brake system data to one or more vehicle electronic control modules. A wireless transceiver is provided and is operably disposed with the brake system components. The wireless transceiver is coupled to receive data from various components of the brake system at the respective and to communicate the data to one or more electronic control units within the vehicle. | 5 |
BACKGROUND
[0001] In a formal or professional environment, garments are often worn for several hours. Over time, as clothing remains on the human body, the apparel becomes an environment suitable for the growth of bacteria and other microbial agents. Associated with the growth of microbes are unpleasant malodors, garment discoloration, and skin infections. As the duration of time an article of clothing is worn grows longer, the infiltration of microbes through base layer apparel into exterior clothing inevitably occurs. Formal and professional apparel generate a warm, moist environment, as multiple layers enclose the body, further encouraging microbial contamination.
[0002] Silver is a known antimicrobial agent, and the medical field has used silver for years to inhibit contamination. Further, the use of silver as an antimicrobial agent does not lead to the development of resistant microbe strains. As such, consumer products have increasingly utilized silver treatments. The textile industry has applied silver, as well as other metals, to develop antimicrobial garments. Treatment solutions featuring silver and other metal-based compounds as well as pre-treated textiles are commercially available, and the prior art teaches methods of manufacturing textiles with antimicrobial agents, such as the embedding approach of U.S. Pat. No. 5,064,599, the synthetic manufacture approach of U.S. Pat. No. 5,888,526, the interstitial precipitation approach of U.S. Pat. No. 6,436,420, or the extrusion approach of U.S. Pat. No. 6,585,843. Other methods teach application of antimicrobial compositions to at least one portion of a selected textile substrate. One such method involves antimicrobial compositions based on ion-exchange compounds to fabrics. Such compounds have included zeolites, zirconium phosphates, calcium phosphates, glasses, or mixtures thereof, as in U.S. Pat. No. 6,499,320, U.S. Pat. No. 6,641,829, and U.S. Patent Application Publication No. 2005/0035327.
[0003] U.S. Pat. No. 6,946,433 discloses a silver-based antimicrobial compound with a resin binder to enhance durability in laundering and drying the treated textile, as does U.S. Pat. No. 7,132,378. U.S. Pat. No. 7,291,570 teaches a textile treatment comprised of other than silver or silver ions. Zinc, iron, copper, nickel, cobalt, aluminum, gold, manganese, magnesium, and other metals have been contemplated in addition to silver for use in treatment of textiles to obtain antimicrobial properties. U.S. Pat. No. 7,335,613 features the step of treating a fiber substrate with an antimicrobial compound comprising a metal complexed with a polymer. U.S. Pat. No. 7,846,856 takes a similar approach, forming the textile fiber itself from an antimicrobial compound and a component polymer, the antimicrobial compound comprising a metal complexed with a polymer. Other methods include that of U.S. Patent Application Publication No. 2007/0154507, which describes the use of silver halide particles bound to the fibers, U.S. Patent Application Publication 2007/0292486, which describes a polymeric matrix comprising silver salt particles applied to a substrate, U.S. Patent Application Publication 2009/0252861, which describes silver salt crystals embedded in an adhesive material covering a sheet of fabric, and U.S. Patent Application Publication No. 2010/0047366, which describes antibacterial fibers spun with zinc sulfide.
[0004] Antimicrobial textiles have also been adapted for use in garments wherein only one portion of the textile is treated. U.S. Patent Application Publication No. 2010/0166832 describes silver-coated nylon fibers that can be used to create fabrics that are coated on only one side. U.S. Pat. No. 6,499,320 describes a garment manufactured through a knitting pattern designed to direct conventional yarns to the exterior of the garment and antimicrobial yarns to its interior, and U.S. Pat. No. 6,602,811 teaches a composite fabric comprised of two distinct layers formed concurrently by knitting a plaited construction.
[0005] Each of the prior art references teaches a method of manufacturing a fabric with antimicrobial properties to inhibit contamination, whether the method involves topical application to a fiber or textile substrate or formation of the textile from fibers manufactured from antimicrobial compounds and other materials. However, although there exist a variety of antimicrobial textile products and methods of their manufacture, these materials have not been adapted for use in conjunction with conventional, aesthetically-pleasing, non-treated exterior material to create a formal or professional garment that is both resistant to microbial contamination on its interior and socially appropriate in outward appearance as formal or professional attire. A need therefore exists for formal and professional apparel that can be worn for prolonged periods of time without generating microbial contamination. The present invention meets this need.
SUMMARY
[0006] The disclosure describes an antimicrobial garment and methods for manufacturing the same. The garment is manufactured by combining an antimicrobial textile with a conventional textile used in formal or professional apparel. The resultant garment thus has at least two textile layers. An interior layer features an applied antimicrobial treatment, an antimicrobial textile, or antimicrobial textile fibers woven into a fabric. An exterior layer is comprised of conventional textile material of the type typical of formal or professional apparel, in addition to other materials necessary to complete the garment. The layers are combined and tailored into a complete garment.
[0007] Additional features and advantages are described herein, and will be apparent from, the following Detailed Description and the figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a view of a garment according to one embodiment of the present invention.
[0009] FIG. 2 is a partial section of a garment according to one embodiment of the present invention
[0010] FIG. 3 is a partial section of a garment according to one embodiment of the present invention.
[0011] FIG. 4 is a view of a garment according to one embodiment of the present invention.
[0012] FIG. 5 is a view of a garment according to one embodiment of the present invention.
[0013] FIG. 6 is a view of a garment according to one embodiment of the present invention.
DETAILED DESCRIPTION
[0014] Various embodiments and applications thereof, as herein described, are not intended to be limiting; rather, the scope of the invention is limited only by the scope of the appended claims. Further, any referenced examples are only intended to describe some of the various embodiments of the claimed invention and are not intended to be limiting.
[0015] Referring to FIG. 1 , an embodiment of a garment 10 is shown in accordance with the present invention. An antimicrobial treatment, typically silver or metal-based, is applied to a selected textile to create an interior layer 12 . Alternatively, the interior layer 12 may be comprised of a textile having antimicrobial properties or antimicrobial textile fibers woven into a fabric. Like the textile receiving topical application of an antimicrobial treatment, these alternative embodiments exhibit the desired antimicrobial properties and similarly resist contamination, discoloration, and malodors. A second textile is selected for use as an exterior layer 14 . The exterior layer 14 is of a type typically used in formal or professional apparel and provides the garment 10 with an acceptable outward appearance that is appropriate for the formal or professional environment in which the garment 10 is intended to be worn. At least one interior layer 12 is fastened to at least one exterior layer 14 with a fastener 16 . Together, the layers are tailored into a garment 10 .
[0016] The antimicrobial treatment is a metal-based compound, preferably silver-based, and resists bacterial or other microbial contamination despite prolonged contact with human skin in a warm, moist environment. Any antimicrobial treatment is acceptable for use. The preferred embodiment employs antimicrobial nanoparticles available in a water-dispersible powder from NanoHorizons, Inc. under the trade name SmartSilver™. In response to moisture, such as perspiration, the antimicrobial treatment releases silver ions, which destroy the microbes. Any method of application of an antimicrobial compound may be utilized.
[0017] The interior layer 12 is comprised of any textile or combination of textiles, whether the textile possesses antimicrobial properties or requires antimicrobial treatment. Such textiles include silk, rayon, cotton-backed satin, viscose, emerzine, cupro/cupramonium rayon (bemberg), wood pulp, cotton, alpara, polyester, acetate poult, acetate microfiber, acetate/bemberg, acetate/viscose, bemberg 100% ponginette, bemberg taffeta shot, bemberg twill, silk/viscose, viscose/acetate shot twill, viscose/rayon heavy twill, viscose S/L regency, viscose satin, viscose twill, acetate surah and polyester taffeta; however, any material or combination of materials apparent to those skilled in the art may be utilized, as the embodiment is not limited to any particular material. Textile fibers having antimicrobial properties may alternatively be woven into a fabric to comprise the interior layer 12 .
[0018] Any suitable textile or combination of textiles may be used to comprise the exterior layer 14 . Such textiles include wool, silk, lambswool, angora, merino wool, cashmere, camelhair, covert cloth, worsted flannel, woolen flannel, mohair, worsted spun flannel, worsted spun cashmere, vicuna, cashmere flannel, wool fresco, high twist wool, Harris tweed, cotton corduroy, cotton needle cord, cotton moleskin, linen mohair, linen, cotton, solaro, whipcord, botany wool, serge, kid mohair, mohair barathea, gabardine, super 100 's, super 110 's, super 120 's, super 130 's, super 150 's, super 180 's, super 200 's, wool cheviot, Shetland wool, Scottish tweed, donnegal, moleskin, wool crepe, Irish linen, calvary twill, doeskins, melton, barathea, flax, jute, bamboo and hemp; however, any material or combination of materials apparent to those skilled in the art may be utilized, as the embodiment is not limited to any particular material. Because formal or professional apparel may include more than one interior layer 12 and one exterior layer 14 , the embodiment may comprise additional layers constructed of any additional material necessary to manufacture a complete garment 10 .
[0019] Any suitable fastener 16 may be used to fasten the interior layer 12 to the exterior layer 14 . Such fasteners include stitches, glue, buttons, zippers, snaps, toggles, buckles, tape, hook and loop connectors, or sewing; however any fastener apparent to those skilled in the art may be utilized, as the embodiment is not limited to any particular fastener.
[0020] The interior layer 12 and exterior layer 14 , together with any additional materials necessary to complete the garment 10 , are constructed into a wearable garment 10 . Fastening of the interior layer 12 to the exterior layer 14 with the fastener 16 is undertaken as part of the overall manufacturing process, and does not necessarily constitute an isolated step in the method of manufacture; rather, fastening of the layers and any additional materials may be ongoing as the manufacturing process progresses. Example embodiments include suits, pants or slacks, sport coats, vests, over coats, tuxedos, shirts, neckties, bowties, and other formal or professional apparel featuring at least one interior layer 12 fastened to at least one exterior layer 14 . The present invention includes any of the aforementioned garments or any like garments known to those skilled in the art, so long as the interior layer 12 of the garment 10 possesses antimicrobial properties.
[0021] It should be understood that various changes and modifications to the presently performed embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims. | An antimicrobial garment includes at least two textile layers fastened together, including an interior layer having antimicrobial properties and an exterior layer having a formal or professional aesthetic appearance. The garment is manufactured by either selecting a textile having antimicrobial properties, weaving antimicrobial textile fibers into a fabric, or treating a textile with an antimicrobial treatment, fastening a second textile, and tailoring the combination, together with additional materials as required, into a garment. | 0 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] The present invention contains subject matter related to Japanese Patent Application JP 2008-005574, filed in the Japan Patent Office on Jan. 15, 2008, the entire contents of which being incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an electronic apparatus having a function of transferring information, and an information transfer method.
[0004] 2. Description of the Related Art
[0005] With recent technological development, the amount of data handled on computers has been steadily increasing. This is not only true with the computers but also with televisions and so on that handle video signals, as a result of increasingly improved image quality.
[0006] For example, in “USB (Universal Serial Bus) 2.0,” which is a standard for transferring data between computers and their peripherals, 480 megabits of data must be handled per second. In “high-definition multimedia interface (HDMI),” which is a standard for transferring video between devices, approximately 4.5 gigabits of data must be handled per second, depending on image resolution.
[0007] As means for connecting such devices with each other, connectors or a combination of connectors and cables have been commonly used. However, the increasing rate of signal transfer has caused a need to pay attention to even the structure and precision of the connectors and the structure and manner of twisting of the cables connected to the connectors, as disclosed in Japanese Patent Laid-Open No. 2005-5272, for example, in order to maintain necessary properties.
[0008] As a solution to the above problem, there is a method of inputting and outputting data using noncontact elements such as inductive coupling elements or by radio. For example, Japanese Patent No. 3803364 describes a technique for inputting and outputting the data while supplying power to contactless radio frequency identification (RFID) with the use of a combination of an antenna, a detector diode, and a capacitor.
SUMMARY OF THE INVENTION
[0009] The input and output of the data using the noncontact elements require complicated signal processing such as error correction and equalization, in order to reduce influence of surrounding noise, radio waves emitted from other devices, multipath, and so on. Power that is transferred using the noncontact elements is sufficient for the signal processing in the case where the amount of data processed per unit time is not too great. However, an increase in the amount of data processed per unit time involves an increase in required power, and may result in the power transferred using the noncontact elements being insufficient.
[0010] Moreover, in the case of the input and output of the data using the noncontact elements, it is necessary, when transferring the data, to superimpose control signals necessary for the error correction and synchronization between the devices or the like upon the data, resulting in increased complexity in data generation and data decoding. Furthermore, if an error occurs that cannot be corrected by the error correction for the data, the control signals superimposed upon the data also cannot be obtained, which may result in an inability to transfer the data.
[0011] The present invention addresses the above-identified, and other problems associated with conventional methods and apparatuses, and provides an electronic apparatus and an information transfer method that allow information transfer while making the most use of advantages of both a high-speed transmission path and a secure and reliable transmission path.
[0012] According to one embodiment of the present invention, there is provided an electronic apparatus including: an electrical contact configured to establish an electrical connection with another electronic apparatus to input or output information from or to the other electronic apparatus; a noncontact element configured to input or output information from or to the other electronic apparatus in a noncontact manner; and a signal processing section configured to exercise control over transfer of the information between the electronic apparatus and the other electronic apparatus, while selectively using the electrical contact and the noncontact element.
[0013] According to this electronic apparatus, it is possible to accomplish information transfer while making the most use of advantages of both a high-speed transmission path and a secure and reliable transmission path.
[0014] According to another embodiment of the present invention, there is provided an information transfer method for transferring information between a plurality of electronic apparatuses, each of the electronic apparatuses having an electrical contact configured to establish an electrical connection with another one of the electronic apparatuses to input or output information from or to the other electronic apparatus, and a noncontact element configured to input or output information from or to the other electronic apparatus in a noncontact manner, wherein the information is transferred between the electronic apparatuses, with selective use of the electrical contacts and the noncontact elements.
[0015] According to the above electronic apparatus and information transfer method, it is possible to accomplish information transfer while making the most use of advantages of both a high-speed transmission path and a secure and reliable transmission path.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a block diagram illustrating an information transfer system for electronic apparatuses according to one embodiment of the present invention;
[0017] FIG. 2 is a block diagram illustrating the structure of a signal processing section as shown in FIG. 1 ;
[0018] FIG. 3 is a sequence diagram in the case where data is transferred between the electronic apparatuses using noncontact elements;
[0019] FIG. 4 is a sequence diagram in the case where the data is transferred between the electronic apparatuses using data pins;
[0020] FIG. 5 is a flowchart illustrating a procedure, performed in the electronic apparatus at the transmitting end, from a preparation for data transmission until the data transmission;
[0021] FIG. 6 is a flowchart illustrating a procedure, performed in the electronic apparatus at the receiving end, from a preparation for data reception until the data reception;
[0022] FIG. 7 illustrates a first specific example of the information transfer system for the electronic apparatuses according to one embodiment of the present invention;
[0023] FIG. 8 illustrates a second specific example of the information transfer system for the electronic apparatuses according to one embodiment of the present invention; and
[0024] FIG. 9 illustrates a third specific example of the information transfer system for the electronic apparatuses according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings.
[0026] FIG. 1 is a block diagram illustrating electronic apparatuses and an information transfer system therefor according to one embodiment of the present invention.
[0027] An electronic apparatus 101 includes a signal processing section 106 , a power supply section 107 , a data pin 104 , a power pin 103 , and a noncontact element 105 . An electronic apparatus 101 ′ includes a signal processing section 106 ′, a power supply section 107 ′, a data pin 104 ′, a power pin 103 ′, and a noncontact element 105 ′.
[0028] The signal processing sections 106 and 106 ′ may have different structures depending on specific configurations of the electronic apparatuses 101 and 101 ′. For example, the signal processing sections 106 and 106 ′ perform a process of exchanging data with an external device (which is not an electronic apparatus according to an embodiment of the present invention) via data input/output lines 113 and 113 ′, respectively, and perform various types of signal processing and control for transferring the data between the electronic apparatuses 101 and 101 ′ while selectively using the data pins 104 and 104 ′ and the noncontact elements 105 and 105 ′. More specifically, each of the signal processing sections 106 and 106 ′ may be a microcomputer including a central processing unit (CPU), a random-access memory (RAM), and a read-only memory (ROM), or a logic circuit designed for a specific use.
[0029] The power supply sections 107 and 107 ′ are modules for supplying power for operation to each module in the electronic apparatuses 101 and 101 ′, respectively.
[0030] The data pins 104 and 104 ′ are electrical contacts used to transfer information, such as the data, between the electronic apparatuses 101 and 101 ′. The form, e.g., the number of pins and the shape, of the data pins 104 and 104 ′ may vary depending on the electronic apparatuses 101 and 101 ′.
[0031] The power pins 103 and 103 ′ are electrical contacts used to transfer power for operation between the electronic apparatuses 101 and 101 ′. For example, the power for operation may be supplied from the electronic apparatus 101 to the electronic apparatus 101 ′ via the power pins 103 and 103 ′. Conversely, the power may be supplied from the electronic apparatus 101 ′ to the electronic apparatus 101 .
[0032] The noncontact elements 105 and 105 ′ are used to transfer the information, such as the data, between the electronic apparatuses 101 and 101 ′ in a noncontact manner. The noncontact elements 105 and 105 ′ are elements used for performing noncontact communication, such as electromagnetic coupling-type elements using mutual induction, electromagnetic induction-type elements using electromagnetic induction, electrostatic induction-type elements using electrostatic induction, or optical-type elements.
[0033] In a system of data transfer between the electronic apparatuses according to this embodiment, the data pins 104 and 104 ′ or the noncontact elements 105 and 105 ′ are selectively used to perform the data transfer between the electronic apparatuses 101 and 101 ′.
[0034] Note that each of the electronic apparatuses 101 and 101 ′ has the aforementioned sections, but that the sections in the electronic apparatus 101 may not necessarily be identical to those in the electronic apparatus 101 ′. The data pins 104 and 104 ′ of the electronic apparatuses 101 and 101 ′ may be connected to each other either directly or via a cable. Also, the power pins 103 and 103 ′ of the electronic apparatuses 101 and 101 ′ may be connected to each other either directly or via a cable.
[0035] FIG. 2 is a block diagram illustrating the structure of the signal processing section 106 ( 106 ′). Reference characters outside parentheses are reference characters for the blocks in the signal processing section 106 of the electronic apparatus 101 , whereas reference characters inside the parentheses are reference characters for the blocks in the signal processing section 106 ′ of the electronic apparatus 101 ′. As shown in FIG. 2 , the signal processing section 106 ( 106 ′) includes a data determination block 701 ( 701 ′), an encoding/decoding block 702 ( 702 ′), an input/output switch block 703 ( 703 ′), data lines 704 ( 704 ′), 705 ( 705 ′), and 706 ( 706 ′), and a control line 707 ( 707 ′). The data lines 704 ( 704 ′), 705 ( 705 ′), and 706 ( 706 ′) and the control line 707 ( 707 ′) connect the data determination block 701 ( 701 ′), the encoding/decoding block 702 ( 702 ′), and the input/output switch block 703 ( 703 ′) to one another.
[0036] Each module in the signal processing section 106 ( 106 ′) has a mode for operating as a module at a transmitting end and a mode for operating as a module at a receiving end. When one of the signal processing sections 106 and 106 ′ operates as a unit at the transmitting end, the other of the signal processing sections 106 and 106 ′ operates as a unit at the receiving end. It is assumed in the following description that the signal processing section 106 of the electronic apparatus 101 operates as a unit at the transmitting end, while the signal processing section 106 ′ of the electronic apparatus 101 ′ operates as a unit at the receiving end.
[0037] First, a function of the data determination block 701 in the signal processing section 106 , which operates as a unit at the transmitting end, will now be described below.
[0038] The data determination block 701 determines the type of data that has been inputted thereto from an outside (e.g., a module or device that is not an electronic apparatus according to an embodiment of the present invention) and which is to be transmitted, based on an identifier of the data type described in a header of the data or the like, for example. Examples of the data type include document, image, video, audio, computer program, and stream data. Based on the data type determined, the data determination block 701 determines whether the data is data that should be transferred at a high speed. The data that should be transferred at a high speed is data that involves a speed constraint, such as data that is to be played back in real time at the receiving end. Specific examples of the data that should be transferred at a high speed include video, audio, or other stream data. When determining whether the data is data that should be transferred at a high speed, the data determination block 701 may take a total size of the data into account, instead of simply determining it based on the data type. Also, the data determination block 701 may determine whether the data is data that should be transferred at a high speed, based only on the total size of the data.
[0039] The data determination block 701 has a function of making a preparation for data transmission in a manner described below, based on the result of the above determination.
[0040] In the case where the data to be transmitted is data that should be transferred at a high speed, the data determination block 701 controls the input/output switch block 703 to use the noncontact element 105 when transmitting the data to the electronic apparatus 101 ′ at the receiving end, and instructs the encoding/decoding block 702 to add an error correcting code to the data in order to ensure reliability of the transfer, and to encrypt the data in order to ensure security in the transfer. Meanwhile, in the case where it has been determined that the data to be transmitted is data that does not have to be transferred at a high speed, the data determination block 701 controls the input/output switch block 703 to use the data pin 104 when transmitting the data to the electronic apparatus 101 ′ at the receiving end, and determines whether the data has a high degree of importance, and, if the data has a high degree of importance, instructs the encoding/decoding block 702 to encrypt the data.
[0041] There are several methods that can be employed by the data determination block 701 to determine the degree of importance of the data. For example, the data determination block 701 may determine the degree of importance of the data based on the type of the data. Also, the data transmitted from the external device may have information added thereto about the degree of importance of the data. In this case, the data determination block 701 may determine the degree of importance of the data based on that information.
[0042] In addition, based on the preparation for the data transmission, the data determination block 701 generates a notification that includes information necessary for the electronic apparatus 101 ′ at the receiving end to make a preparation for data reception, and transmits this notification to the electronic apparatus 101 ′ at the receiving end via a transmission path of the data pin 104 . Here, this notification includes: information that specifies whether the electronic apparatus 101 ′ at the receiving end should use the data pin 104 ′ or the noncontact element 105 ′ when receiving the data from the electronic apparatus 101 ; information that indicates whether the data is encrypted or not; information that indicates whether the error correcting code has been added to the data; a secret key used when encrypting the data (in the case where the data is encrypted); and so on.
[0043] The electronic apparatuses 101 and 101 ′ are configured, in their initial state, to use the data pins 104 and 104 ′ when exchanging other information than the data, e.g., the notification, between the electronic apparatuses 101 and 101 ′.
[0044] Next, the data determination block 701 ′ in the signal processing section 106 ′, which operates as a unit at the receiving end, will now be described below.
[0045] The data determination block 701 ′ in the signal processing section 106 ′ at the receiving end has a function of making the preparation for the data reception in a manner described below, based on the information included in the notification acquired from the electronic apparatus 101 at the transmitting end.
[0046] Based on the information included in the acquired notification, the data determination block 701 ′ instructs the input/output switch block 703 ′ to use the specified transmission path, i.e., the noncontact element 105 ′ or the data pin 104 ′, when receiving the data from the electronic apparatus 101 . In addition, in the case where the data determination block 701 ′ has determined that use of the noncontact element 105 ′ is specified, the data determination block 701 ′ instructs the encoding/decoding block 702 ′ to decrypt the data and perform error correction on the data, and passes the secret key included in the acquired notification to the encoding/decoding block 702 ′.
[0047] Meanwhile, in the case where the data determination block 701 ′ has determined that use of the data pin 104 ′ is specified when receiving the data from the electronic apparatus 101 , the data determination block 701 ′ instructs the encoding/decoding block 702 ′ whether or not to decrypt the data, based on the information included in the acquired notification, and if the data is to be decrypted, the data determination block 701 ′ passes the secret key included in the acquired notification to the encoding/decoding block 702 ′.
[0048] The encoding/decoding block 702 ( 702 ′) operates as an encoding block when used at the transmitting end, and as a decoding block when used at the receiving end. In accordance with the instruction from the data determination block 701 , the encoding/decoding block 702 in the signal processing section 106 at the transmitting end adds the error correcting code to the data to be transmitted and encrypts the data. In accordance with the instruction from the data determination block 701 ′, the encoding/decoding block 702 ′ in the signal processing section 106 ′ at the receiving end decrypts the data and performs the error correction on the data.
[0049] In accordance with the instruction from the data determination block 701 ( 701 ′), the input/output switch block 703 ( 703 ′) switches the transmission path for the data transfer between the electronic apparatuses 101 and 101 ′, between the noncontact element 105 ( 105 ′) and the data pin 104 ( 104 ′).
[0050] Next, operations of the electronic apparatuses 101 and 101 ′ according to this embodiment of the present invention will now be described below.
[0051] It is assumed in the following description that the electronic apparatus 101 is the transmitter of the data, whereas the electronic apparatus 101 ′ is the receiver of the data. Here, as noted previously, the data to be transmitted and received refers to the document, the image, the video, the audio, the computer program, the stream data, or the like, and does not refer to the notification that is exchanged between the electronic apparatuses 101 and 101 ′, before or after the data transfer therebetween, for the control of the data transfer.
[0052] FIG. 3 is a sequence diagram in the case where the data is transferred between the electronic apparatuses 101 and 101 ′ using the noncontact elements 105 and 105 ′. FIG. 4 is a sequence diagram in the case where the data is transferred between the electronic apparatuses 101 and 101 ′ using the data pins 104 and 104 ′.
Preparation for Data Transmission
[0053] First, the operation of the preparation for the data transmission ( FIG. 3 : 301 ) in the signal processing section 106 in the electronic apparatus 101 at the transmitting end will now be described below. FIG. 5 is a flowchart illustrating a procedure, performed in the electronic apparatus 101 at the transmitting end, from the preparation for the data transmission ( FIG. 3 : 301 , FIG. 4 : 401 ) until the data transmission ( FIG. 3 : 306 , FIG. 4 : 406 ).
[0054] The signal processing section 106 in the electronic apparatus 101 at the transmitting end receives, from the outside (e.g., the module or device that is not an electronic apparatus according to an embodiment of the present invention) via the data input/output line 113 , the data to be transmitted ( FIG. 5 : step S 501 ), and the data determination block 701 determines whether the inputted data is data that should be transferred at a high speed, based on the type of the data, the total size of the data, or the like ( FIG. 5 : step S 502 ).
[0055] In the case where the data determination block 701 has determined that the inputted data is data that should be transferred at a high speed, the data determination block 701 instructs, via the control line 707 , the input/output switch block 703 to use the transmission path of the noncontact element 105 when transmitting the data to the electronic apparatus 101 ′ at the receiving end, as illustrated in FIG. 3 ( FIG. 5 : step S 503 ). In addition, the data determination block 701 instructs, via the control line 707 , the encoding/decoding block 702 to add the error correcting code to the data to be transmitted ( FIG. 5 : step S 504 ). Generally speaking, in wireless data communication, such as that which uses the noncontact elements, transmission characteristics are easily affected by a noise environment. As such, the reliability of the data transfer can be increased by adding the error correcting code to the data at the transmitting end and performing the error correction on the data at the receiving end, as described above.
[0056] Next, the data determination block 701 configures itself to output the data to the encoding/decoding block 702 via the data line 705 , and instructs, via the control line 707 , the encoding/decoding block 702 to transmit the data from the encoding/decoding block 702 to the input/output switch block 703 via the data line 706 ( FIG. 5 : step S 505 ). In the above-described manner, the data determination block 701 performs settings so that the data to be transmitted will be outputted to the input/output switch block 703 through the encoding/decoding block 702 .
[0057] Next, the data determination block 701 instructs, via the control line 707 , the encoding/decoding block 702 to encrypt the data to which the error correcting code has been added ( FIG. 5 : step S 506 ). Further, the data determination block 701 instructs, via the control line 707 , the encoding/decoding block 702 to pass the secret key used when encrypting the data to the data determination block 701 , thereby acquiring the secret key from the encoding/decoding block 702 ( FIG. 5 : step S 507 ). The preparation for the data transmission ( FIG. 3 : 301 ) in the electronic apparatus 101 at the transmitting end is complete at this stage, in the case where the inputted data is data that should be transferred at a high speed.
[0058] Thereafter, based on the above-described preparation for the data transmission, the data determination block 701 generates the notification that includes the information that is necessary for the electronic apparatus 101 ′ at the receiving end to make the preparation for the data reception, passes the notification to the input/output switch block 703 via the data line 704 , and instructs, via the control line 707 , the input/output switch block 703 to transmit the notification to the electronic apparatus 101 ′ at the receiving end via the transmission path of the data pin 104 . In accordance with this instruction, the input/output switch block 703 transmits the notification passed from the data determination block 701 to the electronic apparatus 101 ′ at the receiving end via the transmission path of the data pin 104 ( FIG. 3 : 302 , FIG. 5 : step S 511 ). This notification includes: information that specifies that the electronic apparatus 101 ′ at the receiving end should use the transmission path of the noncontact element 105 ′ for the data transfer; information that indicates that the data is encrypted; information that indicates that the error correcting code is added to the data; and the secret key used when encrypting the data.
[0059] Meanwhile, in the case where the data determination block 701 has determined at step S 502 that the inputted data is data that does not have to be transferred at a high speed, the data determination block 701 instructs, via the control line 707 , the input/output switch block 703 to use the transmission path of the data pin 104 to transmit the data to the electronic apparatus 101 ′ at the receiving end, as illustrated in FIG. 4 ( FIG. 5 : step S 508 ).
[0060] Next, based on the degree of importance of the data to be transmitted, the data determination block 701 determines whether this data is data that should be encrypted ( FIG. 5 : step S 509 ). In the case where this data is data that should be encrypted, the data determination block 701 configures itself to output the data to the encoding/decoding block 702 via the data line 705 , and instructs, via the control line 707 , the encoding/decoding block 702 to transmit the data from the encoding/decoding block 702 to the input/output switch block 703 via the data line 706 ( FIG. 5 : step S 505 ).
[0061] Next, the data determination block 701 instructs, via the control line 707 , the encoding/decoding block 702 to encrypt the data ( FIG. 5 : step S 506 ), and instructs, via the control line 707 , the encoding/decoding block 702 to pass the secret key used when encrypting the data to the data determination block 701 , thereby acquiring the secret key from the encoding/decoding block 702 ( FIG. 5 : step S 507 ). The preparation for the data transmission ( FIG. 4 : 401 ) in the electronic apparatus 101 at the transmitting end is complete at this stage, in the case where data that does not have to be transferred at a high speed but should be encrypted is to be transferred.
[0062] Thereafter, based on the above-described preparation for the data transmission, the data determination block 701 generates the notification that includes the information that is necessary for the electronic apparatus 101 ′ at the receiving end to make the preparation for the data reception, passes the notification to the input/output switch block 703 via the data line 704 , and instructs, via the control line 707 , the input/output switch block 703 to transmit the notification to the electronic apparatus 101 ′ at the receiving end via the transmission path of the data pin 104 . In accordance with this instruction, the input/output switch block 703 transmits the notification passed from the data determination block 701 to the electronic apparatus 101 ′ at the receiving end via the transmission path of the data pin 104 ( FIG. 4 : 402 , FIG. 5 : step S 511 ). This notification includes: information that specifies that the electronic apparatus 101 ′ at the receiving end should use the data pin 104 ′ for the data transfer; the information that indicates that the data is encrypted; information that indicates that the error correcting code is not added to the data; and the secret key used when encrypting the data.
[0063] Meanwhile, in the case where it is determined at step S 509 that the data to be transmitted does not have to be encrypted, the data determination block 701 configures itself to output the data to the input/output switch block 703 via the data line 704 ( FIG. 5 : step S 510 ). The preparation for the data transmission ( FIG. 4 : 401 ) in the electronic apparatus 101 at the transmitting end is complete at this stage, in the case where data that does not have to be transferred at a high speed or encrypted is to be transferred.
[0064] Next, based on the above-described preparation for the data transmission, the data determination block 701 generates the notification that includes the information that is necessary for the electronic apparatus 101 ′ at the receiving end to make the preparation for the data reception, passes the notification to the input/output switch block 703 via the data line 704 , and instructs, via the control line 707 , the input/output switch block 703 to transmit the notification to the electronic apparatus 101 ′ at the receiving end via the transmission path of the data pin 104 . In accordance with this instruction, the input/output switch block 703 transmits the notification passed from the data determination block 701 to the electronic apparatus 101 ′ at the receiving end via the transmission path of the data pin 104 ( FIG. 4 : 402 , FIG. 5 : step S 511 ). This notification includes: information that specifies the use of the data pin for the data transfer; information that indicates that the data is not encrypted; and the information that indicates that the error correcting code is not added to the data.
Preparation for Data Reception
[0065] Next, an operation of the preparation for the data reception ( FIG. 3 : 303 , FIG. 4 : 403 ) in the signal processing section 106 ′ in the electronic apparatus 101 ′ at the receiving end will now be described below. FIG. 6 is a flowchart illustrating a procedure, performed in the electronic apparatus 101 ′ at the receiving end, from the preparation for the data reception ( FIG. 3 : 303 , FIG. 4 : 403 ) until the data reception ( FIG. 3 : 307 , FIG. 4 : 407 ).
[0066] In the signal processing section 106 ′ in the electronic apparatus 101 ′ at the receiving end, the input/output switch block 703 ′ is configured, in its initial state, to use the transmission path of the data pin 104 ′ to exchange the information with the electronic apparatus 101 at the transmitting end. Accordingly, the notification from the electronic apparatus 101 at the transmitting end is passed to the signal processing section 106 ′ in the electronic apparatus 101 ′ at the receiving end via the data pins 104 and 104 ′ ( FIG. 6 : step S 601 ). In addition, in the initial state, the input/output switch block 703 ′ is configured to pass the inputted information to the data determination block 701 ′ via the data line 704 ′. Accordingly, the notification from the electronic apparatus 101 at the transmitting end is passed from the input/output switch block 703 ′ to the data determination block 701 ′ via the data line 704 ′.
[0067] Based on the information included in the acquired notification, the data determination block 701 ′ determines which of the transmission path of the noncontact element 105 ′ and the transmission path of the data pin 104 ′ is to be used to receive the data from the electronic apparatus 101 at the transmitting end ( FIG. 6 : step S 602 ). If the data determination block 701 ′ determines that the use of the noncontact element 105 ′ is specified, the data determination block 701 ′ instructs, via the control line 707 ′, the input/output switch block 703 ′ to use the noncontact element 105 ′ ( FIG. 6 : step S 603 ). In addition, the data determination block 701 ′ considers that the data that is to be transmitted from the electronic apparatus 101 is encrypted and has the error-correcting code added thereto, and instructs, via the control line 707 ′, the encoding/decoding block 702 ′ to perform the error correction on the data ( FIG. 6 : step S 604 ).
[0068] Note that it has been assumed in this embodiment that, when the data determination block 701 ′ has determined that the use of the transmission path of the noncontact element 105 ′ by the electronic apparatus 101 ′ at the receiving end is specified for receiving the data from the electronic apparatus 101 at the transmitting end, the data determination block 701 ′ always determines that the data that is to be transmitted from the electronic apparatus 101 is encrypted and has the error-correcting code added thereto. Note, however, that the data determination block 701 ′ may determine whether the data is encrypted or not and whether the error correcting code has been added to the data, based on information concerning the decoding included in the acquired notification, i.e., the information indicating whether the data is encrypted or not and the information indicating whether the error correcting code has been added to the data.
[0069] Further, the data determination block 701 ′ instructs, via the control line 707 ′, the input/output switch block 703 ′ to pass the data to the encoding/decoding block 702 ′ via the data line 706 ′, and configures itself to receive an output from the encoding/decoding block 702 ′ via the data line 705 ′ ( FIG. 6 : step S 605 ).
[0070] Next, the data determination block 701 ′ instructs, via the control line 707 ′, the encoding/decoding block 702 ′ to decode the data (i.e., decrypt the encrypted data) ( FIG. 6 : step S 606 ). Then, the data determination block 701 ′ instructs, via the control line 707 ′, the encoding/decoding block 702 ′ to receive the secret key ( FIG. 6 : step S 607 ), and passes the secret key included in the notification to the encoding/decoding block 702 ′ via the data line 705 ′. The preparation for the data reception ( FIG. 3 : 303 ) in the electronic apparatus 101 ′ at the receiving end is complete at this stage, in the case where the electronic apparatus 101 ′ at the receiving end uses the transmission path of the noncontact element 105 ′ when receiving the data.
[0071] Thereafter, the data determination block 701 ′ transmits, to the electronic apparatus 101 at the transmitting end via the transmission path of the data pin 104 ′, a notification that indicates that the preparation for the data reception has been completed in the electronic apparatus 101 ′ at the receiving end ( FIG. 3 : 304 , FIG. 6 : step S 611 ).
[0072] Meanwhile, if the data determination block 701 ′ determines at step S 602 that the transmission path of the data pin 104 ′ should be used when receiving the data from the electronic apparatus 101 at the transmitting end, the data determination block 701 ′ instructs, via the control line 707 ′, the input/output switch block 703 ′ to use the transmission path of the data pin 104 ′ ( FIG. 6 : step S 608 ).
[0073] Next, based on the information included in the acquired notification, the data determination block 701 ′ determines whether the data that is to be received is encrypted ( FIG. 6 : step S 609 ). If the data determination block 701 ′ determines that the data that is to be received is encrypted, the data determination block 701 ′ instructs, via the control line 707 ′, the input/output switch block 703 ′ to pass the received data to the encoding/decoding block 702 ′ via the data line 706 ′, and configures itself to receive the output from the encoding/decoding block 702 ′ via the data line 705 ′ ( FIG. 6 : step S 605 ).
[0074] Next, the data determination block 701 ′ instructs, via the control line 707 ′, the encoding/decoding block 702 ′ to decode the data (i.e., decrypt the encrypted data) ( FIG. 6 : step S 606 ). Then, the data determination block 701 ′ instructs, via the control line 707 ′, the encoding/decoding block 702 ′ to receive the secret key needed to decrypt the encrypted data ( FIG. 6 : step S 607 ), and passes the secret key included in the notification to the encoding/decoding block 702 ′ via the data line 705 ′. The preparation for the data reception ( FIG. 4 : 403 ) in the electronic apparatus 101 ′ at the receiving end is complete at this stage, in the case where the electronic apparatus 101 ′ at the receiving end uses the transmission path of the data pin 104 ′ when receiving the data and the data is encrypted.
[0075] Thereafter, the data determination block 701 ′ transmits, to the electronic apparatus 101 at the transmitting end via the transmission path of the data pin 104 ′, the notification that indicates that the preparation for the data reception has been completed in the electronic apparatus 101 ′ at the receiving end ( FIG. 4 : 404 , FIG. 6 : step S 611 ).
[0076] Meanwhile, if it is determined at step S 609 that the data that is to be received is in plain text, i.e., in unencrypted form, the data determination block 701 ′ instructs, via the control line 707 ′, the input/output switch block 703 ′ to pass the data via the data line 704 ′ (step S 610 ). The preparation for the data reception ( FIG. 4 : 403 ) in the electronic apparatus 101 ′ at the receiving end is complete at this stage, in the case where the electronic apparatus 101 ′ at the receiving end uses the transmission path of the data pin 104 ′ when receiving the data and the data is not encrypted.
[0077] The preparation for the data reception ( FIG. 3 : 303 , FIG. 4 : 403 ) in the electronic apparatus 101 ′ at the receiving end has been described above.
[0078] Thereafter, the signal processing section 106 ′ in the electronic apparatus 101 ′ at the receiving end provides, to the electronic apparatus 101 at the transmitting end via the transmission path of the data pin 104 ′, the notification that the preparation for the data reception has been completed in the electronic apparatus 101 ′ at the receiving end ( FIG. 3 : 304 , FIG. 4 : 404 , FIG. 6 : step S 611 ).
[0079] The signal processing section 106 in the electronic apparatus 101 at the transmitting end receives, from the electronic apparatus 101 ′ at the receiving end via the transmission path of the data pin 104 , the notification of the completion of the preparation for the data reception ( FIG. 5 : step S 512 ). Then, the signal processing section 106 controls the encoding/decoding block 702 to encode the data inputted from the outside via the data input/output line 113 ( FIG. 3 : 305 , FIG. 4 : 405 , FIG. 5 : step S 513 ), in accordance with the instruction concerning the encoding as provided from the data determination block 701 in the preparation for the data transmission ( FIG. 3 : 301 , FIG. 4 : 401 ) (i.e., the instruction as to whether the data should be encrypted or not and the instruction as to whether the error correcting code should be added to the data). Then, the signal processing section 106 controls the encoded data to be transmitted to the electronic apparatus 101 ′ at the receiving end via the transmission path of the noncontact element 105 or the data pin 104 as specified in the preparation for the data transmission ( FIG. 3 : 306 , FIG. 4 : 406 , FIG. 5 : step S 514 ).
[0080] On the other hand, the signal processing section 106 ′ in the electronic apparatus 101 ′ at the receiving end receives the data from the electronic apparatus 101 at the transmitting end via the transmission path or the noncontact element 105 ′ or the data pin 104 ′ as specified in the preparation for the data reception ( FIG. 3 : 303 , FIG. 4 : 403 ). Then, the signal processing section 106 ′ decodes the received data ( FIG. 3 : 307 , FIG. 4 : 407 , FIG. 6 : step S 612 ) in accordance with the instruction concerning the decoding as provided from the data determination block 701 ′ in the preparation for the data reception ( FIG. 3 : 303 , FIG. 4 : 403 ) (i.e., the instruction as to whether the received data should be decrypted, and the instruction as to whether the error correction should be performed on the received data).
[0081] Upon completion of the decoding of the received data, the signal processing section 106 ′ in the electronic apparatus 101 ′ at the receiving end transmits, to the electronic apparatus 101 at the transmitting end via the transmission path of the data pin 104 ′, information about error occurrence, e.g., the number of blocks where an error has been detected in the error correction ( FIG. 3 : 308 , FIG. 4 : 408 ). Upon receipt of the information about the error occurrence from the electronic apparatus 101 ′ at the receiving end, the signal processing section 106 in the electronic apparatus 101 at the transmitting end evaluates the information about the error occurrence in accordance with a predetermined criterion, to determine whether retransmission of the data is necessary ( FIG. 3 : 309 , FIG. 4 : 409 ). If the signal processing section 106 determines that the retransmission of the data is necessary, the signal processing section 106 transmits the data via the same transmission path as in the previous transmission of the data.
[0082] As described above, according to this embodiment, the high-speed data does not pass through the data pins 104 and 104 ′ of the electronic apparatuses 101 and 101 ′. Thus, inexpensive data pins with a relatively simple structure may be used as the data pins 104 and 104 ′, and accordingly, an inexpensive substrate may be used as a substrate on which the data pins 104 and 104 ′ are installed.
[0083] In addition, according to this embodiment, it is possible to use the optimum transmission path for the data transfer, depending on characteristics of the data transferred or characteristics of the data transfer. For example, it is possible to transfer low-speed data, data that does not permit an error in transmission, highly confidential data, or the like via the transmission path of the data pins 104 and 104 ′, and to transfer the high-speed data that cannot be transferred via the inexpensive data pins with a relatively simple structure via the transmission path of the noncontact elements 105 and 105 ′. Furthermore, when transferring the data via the transmission path of the data pins 104 and 104 ′, complicated signal processing, such as the error correction or the equalization, is not necessary, leading to a reduction in load of the signal processing at the time of the data transfer.
[0084] Still further, according to this embodiment, the notifications that are necessary to start or complete the control for the data transfer can be exchanged between the electronic apparatuses 101 and 101 ′ securely via the transmission path of the data pins 104 and 104 ′ before or after the data transfer, in the case where the data is transferred via the transmission path of the noncontact elements 105 and 105 ′.
[0085] Still further, according to this embodiment, the power is supplied from one of the electronic apparatuses 101 and 101 ′ to the other one of the electronic apparatuses 101 and 101 ′ via the power pins 103 and 103 ′. Thus, supply of higher power is possible than when supplying the power from the electronic apparatus 101 to the electronic apparatus 101 ′ in a noncontact manner, so that sufficient power can be obtained for the signal processing required to transfer the data via the transmission path of the noncontact elements 105 and 105 ′.
[0086] Next, specific examples of the electronic apparatuses and information transfer systems therefor according to embodiments of the present invention will now be described below.
[0087] FIG. 7 illustrates a first specific example. In this example, the electronic apparatus 101 at the transmitting end is a card interface unit of a device such as a computer, while the electronic apparatus 101 ′ at the receiving end is a card-shaped electronic apparatus such as a memory card. The card interface unit 101 is provided with a plurality of power pins 103 and a plurality of data pins 104 , while the card-shaped electronic apparatus 101 ′ is provided with a plurality of power pins 103 ′ and a plurality of data pins 104 ′ corresponding to the power pins 103 and the data pins 104 , respectively, of the card interface unit 101 . Each of the card interface unit 101 and the card-shaped electronic apparatus 101 ′ is provided with the noncontact element 105 or 105 ′, the signal processing section 106 or 106 ′, and the power supply section (not shown). As in the above-described embodiment, the data pins 104 and 104 ′ or the noncontact elements 105 and 105 ′ are selectively used to perform the data transfer between the card interface unit 101 and the card-shaped electronic apparatus 101 ′.
[0088] FIG. 8 illustrates a second specific example. In this example, the electronic apparatus 101 at the transmitting end is a parent substrate such as a motherboard in a computer, while the electronic apparatus 101 ′ at the receiving end is a child substrate connected to this parent substrate. The parent substrate 101 is provided with a connector housing 108 that contains a plurality of power pins and a plurality of data pins internally, while the child substrate 101 ′ is provided with a plurality of power pins 103 ′ and a plurality of data pins 104 ′ corresponding to the power pins and the data pins, respectively, in the parent substrate 101 . Each of the parent substrate 101 and the child substrate 101 ′ is provided with the noncontact element 105 or 105 ′, the signal processing section 106 or 106 ′, and the power supply section (not shown). As in the above-described embodiment, the data pins 104 and 104 ′ or the noncontact elements 105 and 105 ′ are selectively used to perform the data transfer between the parent substrate 101 and the child substrate 101 ′.
[0089] FIG. 9 illustrates a third specific example. In this example, the electronic apparatus 101 at the transmitting end and the electronic apparatus 101 ′ at the receiving end are separate devices that are connected to each other via a cable 110 . Examples of the devices include computers and their peripherals (e.g., printers, scanners, media recorders/players, hard disk drives, communication devices, digital still cameras, digital video cameras, etc.). The devices 101 and 101 ′ are provided with connector housings 109 and 109 ′, respectively, each of which has a plurality of power pins and a plurality of data pins. The connector housings 109 and 109 ′ of the respective devices 101 and 101 ′ can be connected to each other via the cable 110 , which has connectors. Each of the devices 101 and 101 ′ is provided with the noncontact element 105 or 105 ′, the signal processing section 106 or 106 ′, and the power supply section (not shown). As in the above-described embodiment, the data pins in the connector housings 109 and 109 ′ or the noncontact elements 105 and 105 ′ are selectively used to perform the data transfer between the devices 101 and 101 ′.
[0090] Note that it has been assumed in the above-described embodiment that either the transmission path of the data pins or the transmission path of the noncontact elements is used to perform the data transfer. Note, however, that both the transmission paths of the data pins and the noncontact elements may be used at the same time to perform the data transfer. For example, in the case where data that requires transfer at a still higher speed is to be transferred, it may be so arranged that the transmission capacity of the transmission path of the noncontact elements is fully used and that at the same time the transmission path of the data pins is also used in combination, in order to increase the transmission capacity.
[0091] Note that the present invention is not limited to the electronic apparatuses and information transfer methods that have been described above with reference to the accompanying drawings. It should be understood by those skilled in the art that various modifications, combinations, sub-combinations and alterations may occur depending on design requirements and other factors insofar as they are within the scope of the appended claims or the equivalents thereof. | Disclosed herein is an electronic apparatus including: an electrical contact configured to establish an electrical connection with another electronic apparatus to input or output information from or to the other electronic apparatus; a noncontact element configured to input or output information from or to the other electronic apparatus in a noncontact manner; and a signal processing section configured to exercise control over transfer of the information between the electronic apparatus and the other electronic apparatus, while selectively using the electrical contact and the noncontact element. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Ser. No. 11/748,427, filed May 14, 2007; which is a continuation-in-part of U.S. Ser. No. 11/082,384, filed Mar. 17, 2005 and also a continuation-in-part of U.S. Ser. No. 11/005,185, filed Dec. 6, 2004, now U.S. Pat. No. 7,285,407; which is a divisional of Ser. No. 10/163,169 filed Jun. 4, 2002, now U.S. Pat. No. 6,991,843; which is a continuation-in-part of U.S. Ser. No. 09/808,395, filed Mar. 14, 2001, now U.S. Pat. No. 7,048,818. The entire contents of each of the foregoing are hereby incorporated by reference.
TECHNICAL FIELD
[0002] This invention relates to molding apparatus and related methods.
BACKGROUND
[0003] Early male-touch fastener products were generally woven materials, with hooks formed by cutting filament loops. More recently, arrays of small fastener elements have been formed by molding the fastener elements, or at least the stems of the elements, of resin, forming an interconnected sheet of material. Generally, molded plastic hook tape has displaced traditional woven fabric fasteners for many applications, primarily because of lower production costs.
[0004] Molded plastic hook tape is often attached to substrates by employing an adhesive, or by sewing when the substrate is a made from sewable material. Often, adhesive-backed hook tape is utilized to attach the hook tape at desired locations on the substrate. Unfortunately, me process of applying adhesive-backed hook tape can be slow, and adhesion of the adhesive-backed hook tape to the substrate can be poor.
SUMMARY
[0005] Generally, the invention relates to molding apparatus and related methods.
[0006] In one aspect, the invention features a method of molding projections on a substrate. The method includes introducing a substrate having an outer surface into a gap formed between a peripheral surface of a rotating mold roll that defines a plurality of discrete cavities that extend inwardly from the peripheral surface, and a supporting surface. Resin is delivered to a nip formed between the outer surface of the substrate and the peripheral surface of the rotating mold roll. The outer surface of the substrate and the peripheral surface of the rotating mold roll are arranged to generate sufficient pressure to at least partially fill the cavities in the mold roll as the substrate is moved through the gap to mold an array of discrete projections including stems that extend integrally from a layer of the resin bonded to the substrate. The molded projections are then withdrawn from their respective cavities by separation of the peripheral surface of the mold roll from the outer surface of the substrate by continued rotation of the mold roll. The substrate o has a beam stiffness, measured as a product of an overall moment of inertia of a nominal transverse cross-section and an effective modulus of elasticity of a material from which the substrate is formed, that is greater than about 200 lb-in 2 (0.574 N-m 2 ).
[0007] In some embodiments, the beam stiffness is greater than 1,000 lb-in 2 (2.87 N-m 2 ), e.g., 4,000 lb-in 2 (11.48 N-m 2 ) or more, e.g., 8,000 lb-in 2 (22.96 N-m 2 ).
[0008] In some instances, the effective modulus of elasticity of the material from which the substrate is formed is greater than 100,000 psi (6.89×10 8 N/m 2 ), e.g., 250,000 psi (1.72×10 9 N/m 2 ), 750,000 psi (5.17×10 9 N/m 2 ), 1,000,000 psi (6.89×10 9 N/m 2 ) or more, e.g., 5,000,000 psi (3.45×10 10 N/m 2 ), 15,000,000 psi (1.03×10 11 N/m 2 ) or more, e.g., 30,000,000 psi (2.07×10 11 N/m 2 ).
[0009] In some implementations, the supporting surface is a peripheral surface of a counter-rotating pressure roll or a fixed pressure platen.
[0010] In some embodiments, the cavities of the mold roll are shaped to mold hooks so as to be engageable with loops. In other embodiments, the cavities of the mold roll are shaped to mold hooks, and the hooks are reformed after molding.
[0011] In some instances, each projection defines a tip portion, and the method further includes deforming the tip portion of a plurality of projections to form engaging heads shaped to be engageable with loops, or other projections, e.g., of a complementary substrate.
[0012] In some embodiments, the resin is delivered directly to the nip. In some implementations, the resin is delivered first to the outer surface of the substrate upstream of the nip, and then the resin is transferred to the nip, e.g., by rotation of the mold roll.
[0013] The substrates can have a variety of shapes, e.g., the substrate can have an “L” shape, “T” shape or “U” shape in transverse cross-section.
[0014] In some embodiments, the method further includes introducing another resin beneath the resin such that the other resin becomes bonded to the outer surface of the substrate and the resin becomes bonded to an outer surface of the other resin.
[0015] The substrate can have, e.g., an average surface roughness of greater than 1 micron, e.g., 2 micron, 4 micron, 8 micron, 12 micron or more, e.g., 25 micron.
[0016] In some implementations, the substrate is formed from more than a single material.
[0017] In some instances, the projections have a density of greater than 300 projections/in 2 (46.5 projections/cm 2 ).
[0018] In some embodiments, the method further comprises pre-heating the substrate prior to introducing the substrate into the gap, or priming the substrate prior to introducing the substrate into the gap.
[0019] In another aspect, the invention features a method of molding projections on a substrate. The method includes introducing a substrate, e.g., a linear substrate, having an outer surface into a gap formed between a peripheral surface of a rotating mold roll that defines a plurality of discrete cavities that extend inwardly from the peripheral surface, and a supporting surface. The resin is delivered to a nip formed between the outer surface of the substrate and the peripheral surface of the rotating mold roll. The outer surface of the substrate and the peripheral surface of the rotating mold roll are arranged to generate sufficient pressure to at least partially fill the cavities in the mold roll as the substrate is moved through the gap to mold an array of discrete projections including stems extending integrally from a layer of the resin bonded to the substrate. The molded projections are withdrawn from their respective cavities by separation of the peripheral surface of the mold roll from the outer surface of the substrate by continued rotation of the mold roll. The substrate has a beam stiffness sufficiently great that during withdrawal of the molded projections from their respective cavities, the substrate remains substantially linear.
[0020] In some embodiments, the beam stiffness of the substrate, measured as a product of an overall moment of inertia of a nominal transverse cross-section and an effective modulus of elasticity of material of the substrate, is greater than about 200 lb-in 2 (0.574 N-m 2 ).
[0021] In another aspect, the invention features an article having molded fastening projections. The article includes a substrate and an array Of discrete molded projections including stems extending outwardly from and integrally with a molded layer of resin solidified about surface features of the substrate, and thereby securing the projections directly to the substrate. The substrate has a beam stiffness, measured as a product of an overall moment of inertia of a nominal transverse cross-section and an effective modulus of elasticity of a material from which the substrate is made, that is greater than about 200 lb-in 2 (0.574 N-m 2 ).
[0022] In some embodiments,, the beam stiffness is greater than about 1,000 lb-in 2 (2.87 N-m 2 ), e.g., 4,000 lb-in 2 (11.48 N-m 2 ).
[0023] Embodiments may have one or more of the following advantages. Projections can be integrally molded onto substrates, e.g., substrates useful in construction, e.g., wallboard, window frames, panels, of tiles, without the heed for using an adhesive, often reducing manufacturing costs, e.g., by reducing labor costs and increasing throughput. Integrally molding projections often improves adhesion of the molded projections to the substrate and reduces the likelihood of delamination of the molded projections from the substrate during the application of a force, e.g., a peeling force, or a shear force.
[0024] In situ lamination of hook, bands or islands on rigid materials held in a planar orientation or presenting a planar surface, extend in rigid flexible materials is also featured.
[0025] All publications, patent applications, patents, and other references mentioned herein are incorporated by reference herein in their entirety.
[0026] Other features and advantages of the invention will be apparent from the following detailed description, and from the claims.
DESCRIPTION OF DRAWINGS
[0027] FIG. 1 is a side view of a process for molding hooks onto a T-shaped substrate, the process utilizing a fixed pressure platen as a supporting surface for the T-shaped substrate.
[0028] FIG. 1A is a cross-sectional view taken along 1 A- 1 A of FIG. 1 .
[0029] FIG. 1B is an enlarged side view of Area 1 B of FIG. 1 .
[0030] FIG. 1C is a cross-sectional view taken along 1 C- 1 C of FIG. 1 .
[0031] FIG. 2 is a side view of an alternative process for molding hooks onto a substrate, the process utilizing a counter-rotating pressure roll as support for the substrate.
[0032] FIG. 2A is an enlarged, side view of a reforming roll (Area 2 A) of FIG. 2 .
[0033] FIG. 3 is a side view of a process for molding stems onto a substrate.
[0034] FIG. 3A is an enlarged side view of Area 3 A of FIG. 3 , showing a substrate having molded stems.
[0035] FIG. 4 is a side view of a process for reforming the molded stems of FIG. 3 to form engageable projections shaped to be engageable with loops ( FIG. 4B ) or other projections.
[0036] FIG. 4A is an enlarged side view of Area 4 A of FIG. 4 .
[0037] FIG. 4B is an enlarged cross-sectional view of a substrate carrying fibrous loops.
[0038] FIG. 4C is a side view of two substrates having deformed molded stems, illustrating how the two substrates can engage each other.
[0039] FIG. 5 is a side view of a process for molding hooks onto a substrate that utilizes a tie layer.
[0040] FIG. 5A is an enlarged side view of Area 5 A of FIG. 5 .
[0041] FIGS. 6 and 7 are cross-sectional views of planar, laminated substrates, having two and three layers, respectively;
[0042] FIG. 8A is a cross-sectional view of an L-shaped substrate having hooks in which heads are directed in a single direction, and FIG. 8B is a perspective view of the L-shaped substrate of FIG. 8A .
[0043] FIG. 9 is cross-sectional view a U-shaped substrate haying molded projections.
[0044] FIG. 10 is a front view of a fastener element molding apparatus of the present invention applying fastener elements to a planar sheet or work piece.
[0045] FIG. 11 is an isometric view of the apparatus of FIG. 10 illustrating only the fastener element mold roil portion of the apparatus applying engageable fastener elements to a sheet or work piece.
[0046] FIG. 12 is a cross-sectional view of the mold roll of FIG. 11 taken along line 12 - 12 of FIG. 11 .
[0047] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0048] Rigid or elastically stretchable substrates having molded fastener projections, and methods of making the same are described herein. Generally, rigid substrates have a beam stiffness that is sufficiently great such that during withdrawal of the molded projections from their respective cavities, the substrate remains substantially straight, and does not bend away from its support. In other cases, elastically stretchable substrates have flexibility in only one orthogonal direction. The elastic material is arranged with the stretchable direction lying in the cross machine direction.
[0049] Referring collectively to FIGS. 1 and 1 A- 1 C, a process 10 for integrally molding projections, e.g., hooks 12 , onto a substrate 14 , e.g., a T-shaped substrate, includes introducing the substrate 14 that has an outer surface 16 into a gap 18 formed between a peripheral surface 20 of a rotating mold roll 22 and a fixed pressure platen 24 that has a supporting surface 27 . The mold roll 22 defines a plurality of discrete cavities, e.g., cavities 26 in the shape of hooks, that extend inwardly from peripheral surface 20 of the rotating mold roll 22 . An extruder (not shown) pumps resin 30 , e.g., molten thermoplastic resin, through a die 31 where it is delivered to a nip N formed between outer surface 16 of the substrate and peripheral surface 20 of the rotating mold roll 22 . The outer surface 16 of the substrate 14 and peripheral surface 20 of rotating mold roll 22 are arranged to generate sufficient pressure to fill the cavities in the mold roll 22 as substrate 14 is moved through gap 18 to integrally mold an array of discrete hooks 12 , including stems 34 , which extend outwardly from and are integral with a layer 40 that is bonded to outer surface 16 . The molded hooks 12 are withdrawn from their respective cavities 26 by separation of the peripheral surface 20 of the mold roll 22 from outer surface 16 of substrate 14 by continued rotation of mold roll 22 . Substrate 14 has a beam stiffness sufficiently great such that during withdrawal of hooks 12 from their respective cavities, the substrate 14 remains substantially linear, and is not bent away from the supporting surface 27 of fixed pressure platen 24 toward moll roll 22 (indicated by arrow 29 ). For example, substrate 14 has a beam stiffness, measured as a product of an overall moment of inertia of a nominal transverse cross-section and an effective modulus of elasticity (Young's modulus) of a material from which the substrate is formed, that is, e.g., greater than 1,000 lb-in 2 (2.87 N-m 2 ), e.g., 4,000 lb-in 2 (11.48 N-m 2 ) or greater, e.g., 8,000 lb-in 2 (22.96 N-m 2 ). The effective modulus of elasticity of the material from which the substrate is formed is measured using ASTM E111-04 at 25° C. at fifty percent relative humidity, allowing sufficient time for moisture and temperature equilibration.
[0050] In some implementations, the outer surface 16 of substrate 14 , the peripheral surface 20 of the rotating mold roll 22 and the resin 30 are arranged to generate sufficient friction such that the substrate 14 is pulled into and moved through gap 18 , in a direction indicated by arrow 41 , by continued rotation of mold roll 22 .
[0051] In some embodiments, mold roll 22 includes a face-to-face assembly of thin, circular plates or rings (not shown) that are, e.g., about 0.003 inch to about 0.250 inch (0.0762 mm-6.35 mm) thick, some rings having cutouts in their periphery that define mold cavities, and other rings having solid circumferences, serving to close the open sides of the mold cavities and to serve as spacers, defining the spacing between adjacent projections. In some embodiments, adjacent rings are configured to mold hooks 12 such that alternate rows 50 , 52 ( FIG. 1B ) have oppositely directed heads. A fully “built up” mold roll may have a width, e.g., from about 0.75 inch to about 24 inches (1.91 cm-61.0 cm) or more and may contain, e.g., from about 50 to 5000 or more individual rings. Further details regarding mold tooling are described by Fisher, U.S. Pat. No. 4,775,310, the disclosure of which is hereby incorporated by reference herein in its entirety.
[0052] Referring to FIG. 2 , in an alternative embodiment, the supporting surface for substrate 14 is a peripheral surface 54 of a counter-rotating pressure roll 56 . As discussed above, an extruder (not shown) pumps resin through die 31 and delivers the resin 30 to nip N to mold an array of discrete hooks 12 extending integrally from layer 40 that is bonded to the substrate. While an extruder (not shown) can pump resin 30 directly into the nip N, other points of delivery are possible. For example, as shown in FIG. 2 , rather than delivering resin directly to nip N, extruder die 31 can be positioned to deliver resin 30 first to the outer surface 16 of substrate 14 upstream of the nip N. In this embodiment, resin 30 is transferred to nip N by moving substrate 14 through gap 18 . This can be advantageous, e.g., when it is desirable that the resin 30 be somewhat set, e.g., cooled, prior to entering the nip N. In other embodiments, also as shown in FIG. 2 , extruder die 31 is positioned to deliver resin 30 first to the outer surface 20 of the rotating mold roll 22 . In this implementation, resin 30 is transferred to the nip N by rotation of the mold roll 22 .
[0053] Referring particularly to FIG. 2A , in some instances, hooks 71 remain slightly
[0054] deformed after being withdrawn from their respective cavities during separation of the peripheral surface 20 from the outer surface 16 of substrate 14 . To return these hooks to their as-molded shape, the process shown in FIG. 2 can optionally include a reforming roll 70 that reforms deformed hooks 71 with pressure and, optionally, heat as the molded hooks move below the reforming roll 70 . In some instances, it is desirable that the reforming roll 70 be rotated such that it has a tangential velocity that is higher than, e.g., ten percent higher or more, e.g., twenty-five percent higher, than the velocity of the. substrate 14 to aid in the reforming of the deformed hooks. In some instances, reforming roll 70 can be used to maintain substrate 14 in a substantially linear state, by hindering movement of substrate 14 toward the mold roll.
[0055] In some embodiments, the process shown in FIG. 2 can optionally include a counter rotating nip-roller 74 in conjunction with the reforming roll 70 to aid in the moving of substrate 14 through gap 18 .
[0056] Referring now to FIGS. 3 and 3A , in an alternative embodiment, a process 90 for integrally molding projections in the shape of stems 82 onto substrates includes a mold roll 22 that defines a plurality of discrete cavities 80 in the shape of stems 82 that extend inwardly from a peripheral surface 20 of the rotating mold roil 22 . In some instances, removal of molded projections that are in the shape of stems 82 from a mold roll can be easier (relative to projections in the shape of hooks) because the mold roll does not have cavities that have substantial undercuts. As a result, substrate 14 can often have a lower beam stiffness (relative to embodiments of FIGS. 1 and 2 ) and still remain substantially linear during withdrawal of the stems 82 from their respective cavities 80 . For example, the substrate can have a beam stiffness that is, e.g., greater than 200 lb-in 2 (0.574 N-m 2 ), e.g., 1,000 lb-in 2 (2.87 N-m 2 ).
[0057] Referring to FIGS. 4-4C , the projections in the shape of stems 82 that were integrally molded to substrate 14 by the process shown in FIG. 3 can be deformed (such as when a thermoformable resin is employed to mold the stems) by a deforming process 100 . Process 100 can form engaging heads 102 shaped to be engageable with loops 103 that extend from a base 104 of a mating material ( FIG. 4B ), or that are engageable with other projections 102 ′ of a mating substrate 106 ( FIG. 4C ).
[0058] Referring particularly to FIG. 4 , a heating device 110 includes a heat source 111 , e.g., a non-contact heat source, e.g., a flame, an electrically heated wire, or radiant heat blocks, that is capable of quickly elevating the temperature of material that is close to heat source 111 , without significantly raising the temperature of material that is further away from heat source 111 . After heating the stems 82 , the substrate moves to conformation station 112 , passing between conformation roll 114 and drive roll 116 . Conformation roll 114 deforms stems 82 to form engageable heads 102 , while drive roll 116 helps to advance the substrate.
[0059] It is often desirable to chill the conformation roll, e.g., by running cold water through a channel 115 in the center of roll 114 , to counteract heating of conformation roll 114 by the heat of the resin. Process 100 can be performed in line with the process shown in FIG. 3 , or it can be performed as a separate process. Further details regarding this deforming process are described by Clarner, U.S. patent application Ser. No. 10/890,010, filed Jul. 13, 2004, the entire contents of which are incorporated by reference herein.
[0060] Referring now to FIGS. 5 and 5A , in an alternative embodiment, an extruder (not shown) pumps resin 30 through die 31 , and delivers resin 30 to nip N formed between outer surface 16 of substrate 14 and peripheral surface 20 of rotating mold roll 22 . At the same time, a second extruder (not shown) pumps another resin 152 through another die 150 , and delivers the other resin to the nip N such that the other resin 152 is disposed underneath the resin 30 , becoming bonded to the outer surface 16 of substrate 14 (forming layer 160 , e.g., a tie layer), while the resin 30 becomes bonded to an outer surface of the other resin 152 . This is often advantageous, e.g., when adhesion of resin to surface 16 is poor. In some embodiments, a maleated polypropylene, or a blend of maleated polypropylene and polypropylene is used as other resin 152 , and polypropylene is used as resin 30 .
[0061] In any of the above embodiments, suitable materials for forming projections, e.g., hooks 12 or stems 82 , are resins, e.g., thermoplastic resins, that provide the mechanical properties that are desired for a particular application. Suitable thermoplastic resins include polypropylene, polyethylene, acrylonitrile-butadiene-styrene copolymer (ABS), polyamide, e.g., nylon 6 or nylon 66, polyesters, e.g., polyethylene terephthalate (PET) or polybutylene terephthalate (PBT), and blends of these materials. The resin may include additives, e.g., lubricating agents, e.g., silicones or fluoropolymers, solid fillers, e.g., inorganic fillers, e.g., silica or pigments, e.g., titanium dioxide. In some embodiments, lubricating agents are employed to reduce the force required to remove molded hooks to from their respective cavities. In some embodiments, an additive is used to improve adhesion of the resin 30 to substrate 14 , e.g., an anhydride-modified linear low-density polyethylene, e.g., Plexar® PX114 available from Quantum.
[0062] In any of the above embodiments, the overall moment of inertia of the nominal transverse cross-section of the substrate can be greater than 0.00020 in 4 (0.00832 cm 4 ). Examples of substrate inertial moments include 0.00065 in 4 (0.0271 cm 4 ), 0.0050 in 4 (0.208 cm 4 ), 0.040 in 4 (1.67 cm 4 ) and 0.5 in 4 (20.8 cm 4 ).
[0063] In any of the above embodiments, the effective modulus of elasticity of the material from which the substrate can be greater than 100,000 psi (6.89×10 8 N/m 2 ), e.g., 250,000 psi (1.72×10 9 N/m 2 ), 750,000 psi (5.17×10 9 N/m 2 ), 1,000,000 psi (6.89×10 9 N/m 2 ) or more, e.g., 5,000,000 psi (3.45×10 10 N/m 2 ), 15,000,000 psi (1.03×10 11 N/m 2 ) or more, e.g., 30,000,000 psi (2.07×10 11 N/m 2 ). The effective modulus of elasticity of the material from which the substrate is formed is measured using ASTM E111-04 at 25° C. at fifty percent relative humidity, allowing sufficient time for moisture and temperature equilibration.
[0064] In any of the above embodiments, the substrate can be, e.g., a construction material, such as wallboard, window frame, wall panel, floor tile, or ceiling tile.
[0065] In any of the above embodiments, in order to improve adhesion of resin to the substrate, it is often advantageous to mold onto a substrate with an average surface roughness of greater than 1 micron, e.g., 2, 3, 4, 5 micron or more, e.g., 10 micron, as measured using ISO 4288:1996(E).
[0066] In any of the above embodiments, the projections, e.g., hooks 12 or stems 82 , preferably have a density of greater than 300 projections/in 2 (46.5 projections/cm 2 ), e.g., 500 (77.5 projections/cm 2 ), 1,000 (155.0 projections/cm 2 ), 2000 (310.0 projections/cm 2 ) or more, e.g., 3,500 projections/in 2 (542.5 projections/cm 2 ).
[0067] In any of the above embodiments, the substrate can be pre-heated prior to introducing substrate 14 into the gap 18 . Pre-heating is sometimes advantageously used to improve adhesion of the resin 30 (or other resin 152 ) to substrate 14 . It can also be used, when a thermoplastic resin is employed, to prevent over cooling, of the thermoplastic resin before entering the nip N.
[0068] In any of the above embodiments, substrate 14 can be primed, e.g., to improve the adhesion of resin 30 (or 152 ) to substrate 14 . In some embodiments, the priming is performed just prior to introduction of substrate 14 into the gap 18 . Suitable primers include acetone, isobutane, isopropyl alcohol, 2-mercaptobenzothiazole, N,N-dialkanol toluidine, and mixtures of these materials. Commercial primers are available from Loctite® Corporation, e.g., Loctite® T7471 primer.
[0069] While certain embodiments have been described, other embodiments are envisioned.
[0070] While various locations of an extruder head are specifically shown in FIG. 2 , these locations can be applied to any of the embodiments described above.
[0071] As another example, while embodiments have been described in which substrates are formed from a single material, in other embodiments, substrates are formed from multiple materials. For example, the substrates can be formed of wood, metal, e.g., steel, brass, aluminum, aluminum alloys, or iron, plastic, e.g., polyimide, polysulfone, or composites, e.g., composites of fiber and resin, e.g., fiberglass and resin.
[0072] As an additional example, while embodiments have been described in which the base of the fastener is formed of a single layer, in other embodiments, such bases are formed of more than a single layer of material. Referring to FIGS. 6 and 7 , a fastener base bonded to a rigid substrate may be formed of two layers 172 and 174 ( FIG. 6 ), and each layer can be a different kind of resin. In still other embodiments, a substrate may be so formed of three layers 182 , 184 and 186 ( FIG. 7 ). More than three layers are possible.
[0073] As a further example, while substrates have been described that are T-shaped and planar in transverse cross-section, other transverse shapes are possible. Referring to FIGS. 8A and 8B , an L-shaped substrate having hooks in which heads are directed in a single direction is shown. Still other shapes are possible. For example, FIG. 9 shows a U-shaped substrate.
[0074] While the embodiments of FIGS. 1-3 show resin being continuously delivered to nip N, in some instances it is desirable to deliver discrete doses or charges of resin to the substrate, e.g., to reduce resin costs, so that projections are arranged on only discrete areas of the substrate. This can be done, e.g., by delivering the doses or charges through an orifice defined in an outer surface of a rotating die wheel, as described in “Delivering Resin For Forming Fastener Products,” filed Mar. 18, 2004 and assigned U.S. Ser. No. 10/803,682, the entire contents of which are incorporated by reference herein.
[0075] While projections 82 of FIG. 3A are shown to have radiused terminal ends, in some embodiments, projections have non-radiused, e.g., castellated terminal ends, such as some of the projections described in “HOOK AND LOOP FASTENER,” U.S. Ser. No. 10/455,240, filed Jun. 4, 2003, the entire contents of which are incorporated by reference herein.
[0076] Referring to FIGS. 10 , 11 and 12 , for example, a substrate 14 is of planar form as it proceeds through the mold station. In some cases, the substrate may be a widthwise stretchable or flexible web such as a knit loop fabric, or an elastically stretchable substrate or loop material such as is described in parent U.S. Pat. No. 7,048,818 (Krantz). In such cases, a tenter frame 33 maintains the substrate sheet in a width-wise flat condition or, when desired, stretched with as much as 50% or even 100% widthwise elastic extension depending upon the material of the substrate. As shown in FIG. 10 , a cantilever-mounted mold roll 46 a extends inwardly form the edge of substrate 14 or the work piece to the position where a band or bands of molded fastener stems or fully formed molded fastener hooks, are desired.
[0077] Where the band or bands of fastener stems or fully formed hooks are to be applied near the edge of substrate 14 , the required nip forces are sufficiently low that rolls 46 a and 48 a may be supported from one end using suitably spaced bearings of a cantilever mounting. That arrangement is suggested in the solid line diagram of the mounting of mold roll 46 a in FIG. 10 . Where the nip pressure is greater, a cantilever support 35 for a second bearing is employed, as suggested in dashed lines in the figure.
[0078] Referring to FIGS. 10 and 11 , the operation of a molding apparatus is illustrated with substrate 14 being fed through nip N formed by mold roll 46 a arid pressure roll 48 a . Mold roll 46 a extends from frame 36 in a cantilevered fashion, e.g., supported from one side only, so that substrate 14 of width, W.sub.2, greater than the width, W.sub.3, of mold roll 46 a can be processed through nip N without interfering with frame 36 . Typically mold roll 46 has width W.sub.3 of less than approximately 2 ft. The cantilevered support of one or the rolls leaves ah open end of nip N to allow workpieces of substantially greater than either roll 46 a or 48 a to pass through nip N without interfering with support frame 36 . As substrate 14 moves through nip N, cavities 37 of mold roll 46 a are filled, as described below, with molten thermoplastic resin, e.g., polypropylene, to form engageable elements, e.g., hooks which are deposited in a relatively narrow band onto a portion of substrate 14 . The initially molten thermoplastic resin adheres the base of each hook stem to substrate 14 as the thermoplastic resin solidifies, in an in situ bonding action.
[0079] The amount of molten thermoplastic resin delivered to the mold roll determines whether the hooks will form an integral array of thermoplastic resin joined together by a thin base layer which is adhered to the surface of the preformed carrier sheet or substrate 14 or whether the hooks will be separate from one anther, individually adhered to the carrier. For example, as shown in FIG. 4 , a thin layer of thermoplastic resin forms a base layer 122 a integral with the array 125 c of hooks 124 c.
[0080] However, by reducing the amount of thermoplastic resin delivered to the mold roll, joining base layer 122 a can be eliminated so that the base of each molded fastener stem is in situ bounded substrate 14 without thermoplastic resin joining hooks 124 c together.
[0081] Referring now to FIG. 12 , an example of delivery of molten thermoplastic resin to the mold roll 46 a to form fastener elements 124 c on substrate 14 will be described. Molten thermoplastic resin is delivered to mold roll 46 a by extruder 42 . Delivery head 42 a of extruder 42 is shaped to conform with a portion of the periphery of mold roll 46 a to form base layer 122 a and to prevent extruded thermoplastic resin from escaping as it is forced into hook cavities 37 of rotating (counterclockwise) mold roll 46 a . Rotation of mold roll 46 a brings base portions of thermoplastic resin-filled cavities 37 into contact with substrate 14 and the thermoplastic resin is forced (by pressure roll 48 a ( FIG. 10 )) to bond to the surface of substrate 14 . In the case of porous or fibrous substrates, carrier sheets or workpieces, the thermoplastic resin solidifies, portions which have partially penetrated the surface adhere to substrate 14 with further rotation of mold roll 46 a partially solidified molded hooks 124 c or stems are extracted from mold cavities 37 leaving a band of hooks or stems projecting from substrate 14 . By adjusting the space between head 42 a and mold roll 46 , the volume of molten thermoplastic resin delivered, and the speed rotation of mold roll 46 a , an amount of thermoplastic resin beyond the capacity of mold cavities 37 can be delivered to mold roll 46 a . This additional thermoplastic resin resides on the periphery of mold roll 46 a and is brought into contact with substrate 14 to form base layer 122 a of thermoplastic resin from which the stems of the engaging elements 124 c extend. In dashed lines, an alternative method of delivering the molten resin to the mold roll, as described previously above, is also suggested.
[0082] It will be realized that the apparatus of FIGS. 10-12 do not require that substrate 14 be flexible. It may indeed be a rigid workpiece, for instances it may be a construction material such as preformed building siding, roofing material, or a structural member, fed through the molding station on appropriate conveyors. The apparatus of all of the embodiments may be incorporated in a manufacturing line, in which the substrate, carrier or workpiece is a preform, upon which further actions are taken other than in situ bonding of fasteners or fastener stems occurs. The manufacturing line may be, e.g., for manufacture of building siding, roof shingles or packaging sheet or film.
[0083] There are other ways to form e.g. separated parallel linear bands or discrete, disconnected islands of hooks on the above-described substrates within certain broad aspects of the present invention. For example, at dispersed, selected locations across the width of a traveling preformed substrate, e.g. a material defining hook-engageable loops, discrete separate molten resin deposits of the desired form, e.g. of x, y-isolated islands, or in spaced apart parallel bands, may be deposited upon the surface structure of the substrate. Following this, upper portions of the resin deposits, while still molten, or after being reheated by an intense localized flame line, are molded into fastener stems by mold cavities that are pressed against the resin deposits. For instance, at selected widthwise separated locations along a deposit line, as the substrate transits the line, discrete island-form deposits are made; at selected locations. Immediately, with the resin still molten, or after heat activation, the substrate is introduced into a molding nip, formed by a mold roll and a pressure roll. The mold roll; for instance, defines tiny fixed hook fastener cavities as described above, or smaller fastener features, e.g. of less than 0.005 inch height, or similarly shallow cavities for tiny stem preforms, that are aligned to press down upon the resin deposits under conditions in which nip pressure causes the molten resin to enter the cavities at the base of the stem portion of the cavities, and fill the molds, and be molded into a localized dense array of stem preforms or into a localized dense array of fully formed loop-engageable molded hooks. With appropriate amounts of resin in the deposits, a base layer common to all of the molded stems of a discrete island deposit can be formed by the mold roll surface, as may be desired. The mold pressure, simultaneously with the molding, causes the resin to bond firmly to the surface structure of the preformed carrier, effecting in situ lamination, Where the preformed substrate has a fibrous or porous makeup, as with hook-engageable loop material, the nip pressure causes the resin to commingle with the top fibers or other structure that define the surface structure of the substrate, without penetrating the full depth of the substrate. Thus the opposite side of me substrate can remain pristine, free of the molding resin, and, if the opposite surface of the preformed web defines a uniform surface of hook-engageable loops across the full width of the article, the effectiveness of those loops can be preserved while the molded stems or fully molded hooks are molded and in situ bonding occurs.
[0084] With such arrangements it will be understood that the regions of the substrate between the separated islands remain free of the resin from which the hooks or stem preforms are molded. Thus, in the case of elastically stretchy substrate webs or carrier sheet preforms, whether of plain preformed elastomer sheet, or of stretchy hook-engageable loop material, the resin-free regions enable the web to be elastically stretchy, while flexibility of the article in both orthogonal (X,Y) directions in the plane of the web is achieved. Where the preformed carrier web is a non-stretchy, but flexible material, such as a bi-directionally stabilized knit loop product having hook-engageable loops on both sides, the regions between the separated islands enable the finished article to be simply flexible in both X and Y directions in the plane of the fabric.
[0085] In certain embodiments, rather than locating discrete regions of hook cavities on the mold roll, in positions to register with a pre-arranged pattern of resin deposits, the mold roll may simply have an array of mold cavities entirely occupying the mold surface of the roll, or may have, such mold cavities in narrow bands separated by enlarged spacer rings or cross-wise extending ridges, as described above.
[0086] Still other embodiments, are within the scope of the claims that follow. | The invention relates to molding systems and related methods. In one aspect of the invention, a molding apparatus includes a first cylindrical roll that is rotatably coupled to a frame arid an adjacent pressure device, the frame is configured so that a substrate can pass through a nip formed between the first cylindrical roll and the pressure device while a portion of the substrate extends laterally beyond at least the frame and the first cylindrical roll. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from Provisional Application Ser. No. 60/515,753, filed Oct. 30, 2003, which is incorporated herein by reference.
BACKGROUND
[0002] Computers can come in a variety of sizes and configurations, from large desktop units to laptops to smaller sizes. Personal digital assistants (PDAs) and other smaller devices also can have much of the functionality of computers. Computers have various configurations of screens, keys, and other features.
SUMMARY
[0003] The computers described here can be smaller than a currently conventional laptop computers, but can have about any size. They can also include many useful features, including a high-resolution color display, built-in keypad, wireless LAN connection, hi-fidelity audio system, and a multi-gigabyte disk drive. The keypad can be a split keypad on opposite sides of a screen formed in a top face of a computer. The computer can also have various other controls and features, including function keys, scroll wheel, game D-pad, stylus, and fingerprint reader. Speakers can also be built into the top face.
[0004] The computers as described can be self-contained and could be a user's only computer, usable for processes such as for researching and writing school assignments, drawing, painting, online shopping, reading news, chatting, e-mail, listening to music, and watching movies.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a perspective view of a computer.
[0006] FIG. 2 is a plan view of the computer of FIG. 1 .
[0007] FIGS. 3 and 4 are close-up views of portions of the computer shown in FIGS. 1 and 2 .
DETAILED DESCRIPTION
[0008] Referring to FIG. 1 , a computer 10 has a housing 12 with bumpers 14 , 16 around the edges to give the housing a rugged look and to provide shock protection. The housing has a top face and an LCD screen 18 formed in the top face. LCD screen 18 can be provided in portrait orientation as shown here and in application no. 29/192,829, filed Oct. 30, 2003, or in a landscape orientation, as also shown in application no. 29/209,316, filed Jul. 14, 2004 (both of these design patent applications are incorporated herein by reference). The screen has a cold cathode fluorescent lamp (CCFL) backlight with an inverter. Screen 18 can be laterally centered in the housing and can extend for most of the vertical dimension of the housing. The screen can be a resistive 4-wire touch screen. The housing can be made of smooth bright-colored plastic and/or metal.
[0009] The computer can have a fold-over cover (not shown) to protect the LCD screen. The cover can screw onto the housing but is customer-replaceable. The cover can be made with a user's choice of materials: metal, plastic, rubber, spandex, leather, etc. The cover is convenient to use, ensuring it is used regularly to protect the LCD. Users can have a whole collection of covers that they pop on and off to suit their mood or fashion.
[0010] As also shown in FIG. 2 , the computer is balanced so it rests easily in the user's hands when using a built-in keyboard or and does not readily tip when using a stand. The keypad is in the top face of the housing and preferably has a full QWERTY keyboard plus function keys. As also shown in FIGS. 2-4 , the keypad can be split to include a left keypad 20 between a left edge of the screen and a left edge of the housing, and a right keypad 22 between the right edge of the screen and the right edge of the housing, and thus on opposite sides of the screen. General purpose function keys 24 , 26 can be provided on one or both sides, and specific function keys 28 and 30 can be provided on each side for music control, screen brightness, volume control, or other controls.
[0011] The computer controls can also include a game controller-style direction pad (D-Pad) 36 , a thumbwheel 38 that is easily accessible when using the built-in keyboard, and can include a fingerprint reader 40 (including, for example, a thumbprint), or may have some other biological detector for detecting the presence of a particular user to allow use of the computer by that user. Such a detector is not necessary, and other protections, such as password protection, could be used. The computer could also be shared among multiple users, such as in an educational environment, in which case the computer can sense the user biologically and automatically configure itself for the particular sensed user, or configure in one of a number of ways for one of a group of users.
[0012] The computer housing can be designed to be water and grit resistant, meaning that an occasional splash of water or soft drink will not seep into the case and ruin the electronics. Using it at the beach or pool is possible, though it may not necessarily survive a full dunking. The LCD and keyboard have basic rubber gaskets and any external openings for jacks are covered with rubber plugs.
[0013] While a keypad and touch screen are preferably built-in, an optional full-size keyboard and mouse can connect wirelessly via Bluetooth technology. Internet and LAN connectivity is preferably wireless via built-in WiFi (802.11b). Printers can also be connected wirelessly via either Bluetooth or WiFi. For compatibility with existing wired devices, such as cameras, scanners, and printers, a USB port (e.g., 1.1) is also provided.
[0014] The top face of the housing can also include one or more covers for speakers 42 , 44 . Additional outlets can be provided for a card slot 46 and a headphone jack 48 .
[0015] A stylus holder 50 for holding a stylus can also be provided in the top face of the computer.
[0016] The computer preferably does not have any external antennas or other dangling parts that can break off if treated roughly.
[0017] One set of exemplary dimensions is approximately 10″ in length, 9.3″ wide, and less than 1″ thick, e.g., about 0.8″ thick. It is designed to be durable, and able to survive being dropped on the floor, tossed in a backpack, and splashed. Other dimensions are possible, but it is preferably smaller than a typical current laptop, but larger than a PDA.
[0018] The computer preferably runs on the Linux operating system and Java, and should be reliable and secure. The Java run-time environment is designed to allow users to download and run dozens of programs.
[0019] The environment should also be private—the information on the computer can be encrypted and it is preferably unlocked only when a test is met, such as the owner's thumbprint.
[0020] The computer is designed to use low-cost, low-power components. Since long battery life (at least 8 hours) is desired, the system is designed to power on and off components as needed.
[0021] The system can include a WiFi/802.11b PC card with housing-mounted diversity antennas, Bluetooth wireless radio chip with embedded ROM connected via dedicated interface, a shock-mounted PC card disk drive, audio CODEC, audio amp, built-in stereo speakers and microphone, mini stereo headphone, and microphone jacks (some of which are shown above).
[0022] Further components that can be added or provided include FM Radio, WiFi wireless LAN chipset, disk drive, digital camera module and connector with custom FPGA controller, built-in or snap-in power adapter/charger, compact Flash Card slot, V.90 modem and RJ-11 jack, analog joystick, and additional function buttons (e.g., more game controller buttons).
[0023] A slot-loading CD-RW/DVD that optionally snaps on the back of the computer can be provided. The CD/DVD backpack can be added or removed without powering down the computer, so it should use a plug & play interface, such as USB. The backpack may also require an additional internal battery to ensure at least 2 hours of DVD playing time.
[0024] The angle and curve of the housing and the angle of the keypads relative to the edges of the housing are useful for the feel and ergonomics of the computer, in addition to providing an attractive and ornamental appearance. The lateral sides are preferable bowed outwardly (concave) and the top and bottom sides are bowed inwardly (convex). By splitting the keypad and locating it in the upper half of the housing at the proper position in the curve, the computer remains balanced in the user's hands while the user is typing, scrolling, or gaming.
[0025] The computer is preferably built from a two-piece injection molded and machined plastic housing. The two front side panels are covered with customer-replaceable and customizable faceplates. The edges of the housing can include soft elastomeric plastic grips that also protect the edges of the housing. The LCD is also protected with an elastomeric bezel.
[0026] Many details are provide but numerous modifications can be made. It is expected that improvements will be made with future hardware as it becomes available. In addition, not all the components set out above are needed; for example, the keyboard could have fewer keys, certain interfaces and ports could be omitted, and other changes could be made that could add features, or reduce features and cost. | A computers can include a high-resolution color display, built-in keypad, wireless LAN connection, hi-fidelity audio system, and a multi-gigabyte disk drive. The screen can be formed in a top face of a computer and a keypad can be a split on opposite sides of the screen. The computer can also have various other controls and features, including function keys, scroll wheel, game D-pad, stylus, and fingerprint reader. Speaker covers for built-in speakers can be provided in the top face. | 6 |
FIELD OF THE INVENTION
This invention relates to an isothermal ammonia converter, and more particularly to an ammonia converter and method for converting ammonia synthesis loop purge gas containing nitrogen and hydrogen to form additional ammonia.
BACKGROUND OF THE INVENTION
Ammonia is commonly manufactured by reacting nitrogen and hydrogen in a synthesis loop including a compressor, an ammonia synthesis reactor and ammonia condensation and recovery. The unreacted synthesis gas mixture is typically recycled from the ammonia separator to the compressor and back to the reactor. Make-up synthesis gas is continuously added to the synthesis loop to provide fresh hydrogen and nitrogen. Because the synthesis gas contains argon, methane and other inert components, a purge stream is usually taken from the synthesis loop to avoid the excessive buildup of the inerts in the synthesis loop. The purge gas is typically processed in a hydrogen recovery unit, and a hydrogen-enriched stream is recycled to the synthesis loop. In some cases, the purge gas is used directly in the fuel system with or without any additional treatment or hydrogen recovery.
A significant technological advance in the manufacture of ammonia has been the use of a highly active synthesis catalyst comprising a platinum group metal such as ruthenium on a graphite-containing support as described in U.S. Pat. Nos. 4,055,628; 4,122,040; and 4,163,775; all of which are hereby incorporated herein by reference. Also, reactors have been designed to use this more active catalyst, particularly the catalytic reactor bed disclosed in U.S. Pat. No. 5,250,270 which is hereby incorporated herein by reference. Other ammonia synthesis reactors include those disclosed in U.S. Pat. Nos. 4,230,669; 4,696,799; and 4,735,780; and the like.
Ammonia synthesis schemes have also been developed based on the highly active catalyst. In U.S. Pat. No. 4,568,530, stoichiometrically hydrogen-lean synthesis gas is reacted in a synthesis reactor containing the highly active catalyst in the synthesis loop.
In U.S. Pat. No. 4,568,532, an ammonia synthesis reactor based on the highly active catalyst is installed in series in the synthesis loop downstream from a reactor containing the more conventional iron-based synthesis catalyst.
In U.S. Pat. No. 4,568,531, the purge gas removed from the primary synthesis loop is introduced into a second synthesis loop using the more active synthesis catalyst to produce additional ammonia from the purge stream. Another purge stream, significantly reduced in size, is taken from the second synthesis loop to avoid the excessive buildup of inerts. The second synthesis loop, like the primary synthesis loop, employs a recycle compressor to recycle synthesis gas to the active catalyst converters in the second synthesis loop.
It would be very desirable to convert hydrogen and nitrogen in the purge stream from a conventional ammonia synthesis loop into additional ammonia using a once-through reactor which does not require staged cooling and a synthesis gas recycle compressor.
SUMMARY OF THE INVENTION
The present invention is directed to an ammonia converter which can be used to convert ammonia synthesis loop purge gas containing nitrogen and hydrogen to form additional ammonia. The ammonia converter is a shell-and-tube reactor using a platinum group metal ammonia synthesis catalyst in the tubes which are maintained in essentially an isothermal condition by boiling water or another heat transfer fluid on the shell side. The ammonia converter allows the ammonia synthesis process to produce additional ammonia from the synthesis loop purge gas by passing the purge gas through the isothermal ammonia converter. The ammonia converter can be installed as a retrofit modification of an existing ammonia synthesis plant to pass the purge stream or a combination of purge streams from several plants through the isothermal ammonia converter on a once-through basis to form additional ammonia, and reduce the size of the purge gas stream which is either processed further in a hydrogen recovery unit or sent to the fuel system directly.
In one aspect, then, the present invention provides an ammonia converter for converting ammonia synthesis loop purge gas containing nitrogen and hydrogen to form additional ammonia. The ammonia converter is a shell and tube reactor having upright tubes. A source of feed gas contains nitrogen and hydrogen for supply to an inlet of the tubes. Ammonia synthesis catalyst in the tubes is adapted to convert the nitrogen and hydrogen to ammonia as the gas passes through the tubes. A source of saturated boiler feed water supplies boiling water to a shell-side of the reactor to maintain a substantially isothermal shell-side condition and remove heat from the tubes. A tube-side outlet is provided for recovering product gas having an increased ammonia content relative to the feed gas. The catalyst preferably comprises a platinum group metal such as ruthenium supported on graphite. The tubes are preferably sized for containing a catalyst volume, and present an area for heat transfer to the boiling water, to maintain the feed and product gases at a temperature in the range from 315° C. to 435° C. at a reaction pressure from 60 to 210 bar. The pressure of the shell-side boiling water is preferably from 60 to 150 bar. The feed gas preferably comprises synthesis loop purge gas having an ammonia content less than 4 mole percent, and the product gas preferably has an ammonia content from about 15 to about 40 mole percent. The converter can further include an ammonia separator for removing ammonia from the product gas to form an ammonia-lean stream, a hydrogen recovery unit for removing hydrogen from the ammonia-lean stream to form a nitrogen-rich stream, and a compressor for recycling a portion of the nitrogen-rich stream to the feed gas source.
In another aspect, the present invention provides a method for converting ammonia synthesis loop purge gas containing nitrogen and hydrogen to form additional ammonia. The method includes the steps of supplying the synthesis loop purge gas to the inlet of the tubes of the shell and tube reactor of the ammonia converter described above, operating the ammonia converter, and recovering ammonia from the product gas to form an ammonia-lean stream. The method can also include the step of preheating the synthesis purge gas in heat exchange with the product gas. The ammonia recovery step preferably includes cooling the product gas to condense ammonia and separating the liquid ammonia from the ammonia-lean stream. The method can also include the steps of supplying the ammonia-lean stream to a hydrogen recovery unit to form a nitrogen-rich stream and a hydrogen-rich stream, compressing a portion of the nitrogen-rich stream and recycling the compressed nitrogen-rich stream into the preheated synthesis loop purge gas, and recycling the hydrogen-rich stream to the synthesis loop.
In a further aspect of the invention, there is provided a method for retrofitting an ammonia plant having a synthesis loop and a purge gas loop. The retrofit method is particularly applicable to retrofitting an ammonia plant wherein fresh ammonia synthesis gas containing hydrogen and nitrogen is combined in the synthesis loop with first and second recycle streams to form a combined ammonia synthesis gas, the combined ammonia synthesis gas is reacted over ammonia synthesis catalyst to form a converted gas, and a purge gas stream and ammonia are removed from the converted gas to form the first recycle stream; and wherein the purge gas stream is processed in a hydrogen recovery unit to form a nitrogen-rich stream and a hydrogen-rich stream which is supplied to the synthesis loop as the second recycle stream. The retrofit method includes installing a shell and tube reactor having upright tubes containing ammonia synthesis catalyst for once-through conversion of nitrogen and hydrogen in a purge gas feed stream, including the purge gas stream from the synthesis loop, into additional ammonia in a reactor effluent stream. Boiler feed water is supplied to a shell side of the reactor to remove heat from the tubes and maintain a substantially isothermal condition on the shell side. Heat exchangers and a vapor-liquid separator are installed for condensing and recovering ammonia from the reactor effluent stream and forming an ammonia-lean stream. The ammonia-lean stream is passed to the hydrogen recovery unit.
The retrofit method can also include installing a compressor for combining a portion of the nitrogen-rich stream from the hydrogen recovery unit with the purge gas stream from the synthesis loop to form the purge gas feed stream. The heat exchangers installed to condense ammonia from the reactor effluent stream preferably include a heat exchanger for preheating the purge gas stream from the synthesis loop against the reactor effluent stream. The step of supplying boiler feed water preferably includes installation of a steam drum for receiving saturated steam and water from the shell side of the reactor, forming a saturated steam stream, and recycling condensate to the shell side of the reactor. The molar ratio of hydrogen to nitrogen in the purge gas feed stream is preferably less than 2.2. The isothermal reactor preferably operates at a tube-side temperature from 315° C. to 435° C. and pressure from 60 to 210 bar.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic flow sheet of an isothermal ammonia converter installed according to the present invention.
FIG. 2 shows a process flow diagram of an ammonia plant synthesis loop and purge loop in which the purge gas from two synthesis loops is converted to additional ammonia in an isothermal ammonia converter installed according to the principles of one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1, there is shown a process 10 for the once-through isothermal conversion of hydrogen and nitrogen in a purge gas stream to additional ammonia. The purge gas in stream 12 is preheated in feed/effluent exchanger 14 for feed to the tube side of a reactor 16 . A fired heater 17 can be used for additional heating of the purge gas feed stream and/or for startup. The tubes in the reactor 16 are filled with catalyst, and the reactor 16 is kept essentially isothermal by boiling water on the shell side of the reactor. A steam drum 18 is provided to maintain the reactor 16 in a flooded condition. Condensate is circulated to the shell side of the reactor 16 via line 20 , and steam and condensate are returned to the steam drum 18 via line 22 . Make-up boiler feed water is supplied via line 24 . The pressure for steam generation in the reactor 16 is desirably selected to be consistent with the maximum pressure of the boiler feed water available, to minimize the temperature difference between the tube and shell sides of the reactor 16 . As the purge gas passes through the catalyst in the tubes of the reactor 16 , the ammonia concentration is increased from a low inlet concentration, typically from 1 to 10 percent ammonia, to an outlet concentration of at least about 20 percent ammonia, to as high as about 40 percent or more. The ammonia product is recovered by cooling reactor effluent stream 28 in the feed/effluent exchanger 14 , with cooling water in exchanger 30 , and then with ammonia refrigerant in the exchanger 32 . Condensed ammonia is recovered from separator 34 via line 36 . Remaining purge gas separated from the ammonia product is sent to optional hydrogen recovery unit 38 via line 40 . The hydrogen recovery unit 38 is operated conventionally and can also receive additional purge gases, such as, for example, compressed medium pressure flash gases from the ammonia recovery of the main synthesis loop, via line 42 . The hydrogen recovery unit 38 typically produces hydrogen stream 44 , argon stream 46 , fuel gas stream 48 , ammonia stream 50 and nitrogen stream 52 . A portion of the nitrogen stream 52 can be recycled to the suction of the synthesis gas compressor (not shown) via line 54 , and the remaining portion is optionally recycled to the reactor 16 by compression in nitrogen compressor 56 . Recycling the nitrogen to the reactor 16 results in a relatively low H/N ratio, preferably less than 2.2, more preferably about 1.7-1.9, which allows a significant reduction in catalyst volume in reactor 16 .
With reference to FIG. 2, there is shown a schematic process diagram for a two-train ammonia plant retrofitted by installing the once-through ammonia converter of the present invention to convert hydrogen and nitrogen in the combined purge streams from the two trains into additional ammonia. The process 100 includes a compression step 102 in which makeup gas 104 , recycle hydrogen 106 , recycle nitrogen 108 and recycle syngas 110 are compressed to form a feed 112 for conversion step 114 employing a conventional compressor and magnetite catalyst converters. Effluent 116 from the conversion step 114 is cooled and passed through a separator in a high pressure separation step 118 . A purge stream 120 is taken from the vapor phase from the high pressure separation step 118 , and the remainder is recycled to the compression step 102 as the recycle syngas 110 as described above. Liquid from the high pressure separation step 118 is processed in a low pressure separation step 122 to form liquid ammonia 124 and vapor 126 which is processed in ammonia scrubbing step 128 . Vapor 130 essentially free of ammonia is compressed in compression step 132 to produce vapor 134 at a suitable pressure for hydrogen recovery.
Similarly, in a second train, makeup gas 136 and syngas recycle 138 are compressed in compression step 140 to form a feed 142 to a magnetite conversion step 144 . Effluent 146 from the magnetite conversion step 144 is cooled and separated in high pressure separation step 148 , a purge stream 150 is taken off from the vapor from the high pressure separation step 148 , and the remainder recycled as recycle syngas 138 to the compression step 140 . Liquid from the high pressure separation step 148 is processed in low pressure separation step 152 to obtain liquid ammonia 154 and an ammonia-lean vapor 156 for feed to ammonia scrubbing step 158 to form an essentially ammonia-free vapor 160 . Vapor 160 is compressed in compression step 162 to form a vapor 164 at a suitable pressure for hydrogen recovery.
Recycled nitrogen 166 is added to purge gas 120 and purge gas 150 to form feed 168 to a supplemental ammonia conversion step 170 . The supplemental ammonia conversion step 170 includes passing the feed 168 through an isothermal ammonia converter installed according to the present invention, and obtains an effluent 172 containing additional ammonia. The effluent 172 is cooled and ammonia 174 separated therefrom in separation step 176 . Vapor 178 from the separation step 176 is fed to hydrogen recovery unit 180 which also receives vapor 134 and vapor 164 from the respective compression steps 132 and 162 . The hydrogen recovery step includes cryogenic processing or membrane-based recovery to obtain a nitrogen-rich stream 182 and a hydrogen-rich stream 184 . An optional nitrogen-rich product 186 can be taken off from the stream 182 , and another portion 188 is preferably supplied to compression step 190 to produce the nitrogen recycle 166 as describe above. The remaining nitrogen 108 is supplied to the compression step 102 as described above. A helium purge 192 may be taken off from the hydrogen-rich stream 184 and remaining hydrogen 106 is recycled to the compression step 102 as described above. The hydrogen recovery step 180 can also produce a conventional argon-rich stream 194 and a fuel gas stream 196 . Any ammonia 198 obtained from the hydrogen recovery step 180 is supplied to an ammonia storage step 200 with ammonia 125 , 155 and 174 . An ammonia product 202 is obtained from the ammonia storage 200 .
The principles of the invention are illustrated by way of the following example:
EXAMPLE
With reference to FIG. 2, an existing two-train ammonia process was modeled using an ASPEN process simulator. The model was subsequently altered to include a supplemental ammonia conversion step 170 to study a simulation of a retrofit to the existing plant. It was presumed that such a retrofit would reduce the purge rate; reduce energy costs; and increase ammonia production; and by study and calculation, the presumption was confirmed. In the following example, pressures are approximate and pressure drops are mostly ignored.
The supplemental ammonia conversion step 170 that was simulated is based on tubular reactor 16 having vertical tubes as shown in FIG. 1 . In the simulation, feed 168 is preheated to 360° C. in a feed/effluent heat exchanger. On start-up, a fired heater provides the required preheat. Feed 168 (FIG. 2) is fed to the top of the reactor 16 (FIG. 1) and flows downward through reactor tubes filled with a ruthenium-impregnated catalyst.
Since the conversion of nitrogen and hydrogen to ammonia is a highly exothermic reaction, the tubular reactor 16 is designed to absorb the heat generated. Further, it is desirable to maintain the reaction at a constant temperature. Isothermal conditions are closely approximated by maintaining the shell side in a flooded condition with pressurized water at its boiling point. Referring again to FIG. 1, a steam drum 18 is provided in an elevated position relative to the reactor 16 to maintain the reactor 16 in the flooded condition. The heat of the reaction is absorbed by the water and converted to steam for energy efficiency.
By conducting a catalyst optimization study, the preferred volume of catalyst in the tubular reactor was determined to be 2.35 m 3 . The required catalyst volume is relatively constant when the concentration of ammonia in the outlet ranges between 20 and 30 mole percent. In this simulation, the concentration in the reactor effluent 172 was 21.94%. The catalyst volume is further optimized by recycling nitrogen directly to the supplemental ammonia conversion step 170 . The required catalyst volume is minimized when recycled nitrogen 166 flow is controlled to maintain a hydrogen/nitrogen ratio of 1.82 in feed 168 .
The reactor 16 was sized to accommodate 2.35 m 3 of catalyst and to transfer the heat of the reaction, which was 8,714.3 MJ/hr, to pressurized water boiling on the shell side. The pressure for steam generation was chosen to be consistent with the maximum pressure at which boiler feed water was available from the existing plant. By operating the shell side at this practical maximum pressure, the temperature difference between the tube and shell sides of the reactor is minimized. Typically, the shell side would be operated at a pressure between 60 and 150 bar.
The reactor 16 for supplemental ammonia conversion step 170 was modeled as a shell and tube exchanger similar to TEMA type BEM with fixed tube sheets and low chrome tubes with INCONEL safe-ends on both ends. The shell was carbon steel, and the channels and tube sheets were low chrome overlayed with stainless steel. The design pressure for the tubes having a minimum wall thickness of 11.43 mm was 203.9 kg/cm 2 . By simulation it was determined that a reactor 16 having 179 tubes of 102 mm in diameter and about 3 m long would accommodate the preferred catalyst volume and provide sufficient area for heat transfer.
It was determined that the shell extending the length of the tubes would contain an adequate amount of pressurized boiler feed water to absorb the heat of reaction of the simulated ammonia production rate. For boiler feed water at this pressure, the design pressure of the shell is 140.6 kg/cm 2 . The pressure drop through the catalyst is 0.5 kg/cm 2 . Typically, the feed and product gases in the reactor 16 are maintained in a temperature range between 315° C. to 435° C. and in a pressure range between 60 to 210 bar. In this simulation, the feed entered the reactor 16 at 360° C. and exited at 404° C. and 180 bar.
Reactor effluent 172 is cooled to 71° C. in a feed/effluent exchanger; to 38° C. by cooling water; and to 5° C. by ammonia refrigerant, and then directed to separation step 176 , where 79 metric tons/day (mtpd) of ammonia 174 are recovered at 98.6% purity.
According to the principles developed in this simulation, an ammonia plant retrofitted with reactor 16 will have lower purge rates, lower energy costs and higher ammonia production rates. The key advantage of reactor 16 is that it operates on a once-through basis, eliminating the need for multiple reactors with interstage cooling. This is possible because the vertical tube reactor is operated essentially isothermally by boiling pressurized water on the shell side.
The results of the ASPEN simulation are summarized in Table 1. The stream numbers correspond to FIG. 2 and the detailed description of the invention.
TABLE 1
Stream
104
106
108
110
112
116
120
Components
(mole percent)
H2
73.80
82.27
0.26
62.27
65.11
54.60
62.27
N2
24.86
13.01
99.74
18.74
20.13
16.43
18.74
CH4
1.04
0.57
—
9.69
7.59
8.53
9.69
Ar
0.28
0.75
—
3.20
2.50
2.81
3.20
NH3
—
—
—
3.89
2.94
15.69
3.89
He
0.02
3.40
—
2.21
1.72
1.94
2.21
Total Flow
64030
2338
700
245480
312540
312540
6706
(kg/hour)
Temp (° C.)
100
9
23
−1
14
406
−1
Press (kg/cm2)
227.0
227.0
3.4
227.0
227.0
227.0
227.0
Stream
125
134
136
138
142
146
150
Components
(mole percent)
H2
0.04
52.26
74.27
62.07
65.31
53.22
62.07
N2
0.02
17.57
24.76
20.60
21.71
17.67
20.60
CH4
0.07
25.34
0.68
10.79
8.12
9.28
10.79
Ar
—
4.12
0.26
4.38
3.28
3.75
4.38
NH3
99.87
—
—
1.70
1.24
15.69
1.70
He
—
0.71
0.03
0.46
0.34
0.39
0.46
Total Flow
59834
538
64815
225030
289840
289840
4343
(kg/hour)
Temp (° C.)
1
180
100
−25
5
370
−25
Press (kg/cm2)
19.1
71.4
199.0
199.0
199.0
119.0
199.0
Stream
155
164
166
168
172
174
178
186
Components
(mole percent)
H2
0.03
50.05
0.26
54.23
36.25
0.46
44.06
0.26
N2
0.01
18.96
99.74
29.77
25.98
0.39
31.55
99.74
CH4
0.04
24.76
—
8.81
10.45
0.48
12.63
—
Ar
0.01
6.09
—
3.17
3.77
0.07
4.58
—
NH3
99.91
—
—
2.67
21.94
98.60
5.23
—
He
—
0.12
—
1.35
1.60
—
1.95
—
Total Flow
60146
327
4398
15447
15447
3138
12309
258
(kg/hour)
Temp (° C.)
−24
143
60
−2
380
5
5
23
press (kg/cm2)
19.1
71.4
184.0
184.0
183.5
182.5
182.5
3.4
Stream
188
194
196
198
202
Components
(mole percent)
H2
0.26
—
7.24
—
0.05
N2
99.74
—
15.85
—
0.02
CH4
—
—
74.88
—
0.07
Ar
—
100.00
1.60
—
0.01
NH3
—
—
0.17
100.00
99.85
He
—
—
0.26
—
—
Total Flow
4398
1436
2819
748
123870
(kg/hour)
Temp (° C.)
23
−100
9
30
−11
Press (kg/cm2)
3.4
3.41
3.4
16.0
16.0
The present invention is illustrated by way of the foregoing description and example. Various modifications will be apparent to those skilled in the art in view thereof. It is intended that all such variations within the scope and spirit of the appended claims be embraced thereby. | A vertical tubular reactor for converting ammonia synthesis loop purge gas to ammonia; a method for converting ammonia synthesis loop purge gas to form additional ammonia; and a method for retrofitting a conventional ammonia plant having a synthesis loop using an iron-based synthesis catalyst and having a purge gas stream, the method including a supplemental ammonia converter for the purge gas stream. The supplemental ammonia converter is a shell and tube reactor. The tubes are filled with a catalyst comprising a platinum group metal such as ruthenium. The tubes are maintained in a substantially isothermal condition by boiling water in the shell side. As a retrofit modification to an existing ammonia synthesis plant, the purge stream is passed through the supplemental ammonia converter on a once-through basis to form additional ammonia and reduce the amount of purge gas. Advantages of the retrofit modification include lower energy consumption, lower purge rates and higher ammonia production rates. | 8 |
This application claims priority of PCT application PCT/CH2007/000559 having a priority date of Mar. 27, 2007, the disclosure of which is incorporated herein by reference.
TECHNICAL FIELD
The invention relates to a device for controlling the transverse movement of the warp threads of a textile weaving machine, in particular of a textile weaving machine having individual heddle movement.
BACKGROUND OF THE INVENTION
Devices for controlling the transverse movement of the warp threads of textile weaving machines, in particular of weaving machines having individual heddle movement, are basically known from numerous documents. In many of these publications, attempts are made to put forward suitable proposals so that the problematic weaving harness of a shedding device of a Jacquard machine can be dispensed with.
EP 0 353 005 A1 discloses a drive arrangement for controlling the transverse movement of the warp threads, in which, with a linear motor, a closed drive cord for the heddles which is guided via four rotating rollers is proposed. However, the implementation of the invention disclosed in EP 0 353 005 A1 comes up against difficulties which are based, on the one hand, on the fact that, with a relatively large number of warp threads arranged next to one another, sufficient space could not be made available for a large number of linear motors, but also for the deflecting rollers, and, on the other hand, on the fact that the deflection of the linear motors proposed there was, in a justifiable version, too small for the necessary transverse movements of the warp threads.
It is known from WO-A-98/24955 to tension-mount the driving part of a weaving machine—in this case, a heddle or a heddle shaft—between two spring parts and to provide an electric drive which raises or lowers the driving part, together with the warp threads, for shedding purposes. This invention also discloses the proposal to design the above-described arrangement as a free oscillator such that a large part of the kinetic energy from the elastic spring force is applied, while the electric drive is intended rather as compensation for the energy losses and to activate the corresponding device. However, the version with the two springs in WO-A-98/24955 likewise takes up a relatively large amount of space, as may also be gathered from the drawings there. Furthermore, it seems difficult, in the arrangement proposed in WO-A-98/24955, on the one hand, to keep the build of the electric motor small, but, on the other hand, to design it with such high power and high movement that it fulfills the requirements when a multiplicity of warp threads lying next to one another are to undergo shedding.
Further publications, such as, for example, WO-A-/11327 or WO-A-2006/114188, are likewise concerned with a free oscillator arrangement, but without being able to solve the problems mentioned above.
EP 1 063 326 A1 discloses cord drives for the heddles of a textile weaving machine having individual heddle movement, and it is proposed there to wind the cords on one side onto electromotively driven cord rollers and to keep them tensioned on the other side by means of a helical spring fastened to the loom. However, the principles of a free oscillator, which are already known from the document mentioned above, are not implemented by means of the device from EP 1 063 326 A1.
Finally, WO-A-2006/063584 discloses a shedding device with individual thread control, in which, in a basically known way, a lifting spring frame or a fixed spring frame with a retaining element for the individual heddles is proposed. However, this type of shedding has proved to be susceptible to faults, since the retaining elements mentioned are basically temperamental.
EP 0 347 626 A2 and DE 198 49 728 A1 disclose electromotive drives for the shedding of weaving machines, which have a coil and a sheet-like permanent magnet, by means of which a rotational movement is proposed for shedding. In this case, a lever action (step-up) is proposed in EP 0 347 626 A2.
SUMMARY OF THE INVENTION
The object of the invention is to improve a device for controlling the transverse movement of the warp threads of a textile weaving machine, in particular of a textile weaving machine having individual heddle movement.
In this case, the measures of the invention result, in the first place, in a very low space requirement, along with a high weaving speed. Due to the register-like fanning out of the heddle drives and to the spring assistance, it is possible to keep the electric drive motors small. Moreover, owing to the lever-like intensification, it becomes possible for the drive travel of these motors to be kept small.
It is advantageous if one at least double step-up is provided, that is to say a movement of the electric motors causes an at least twice as great a movement of the heddles.
A refinement with pull and push rods as force transmission elements for the drive of the driving elements, which may be generally conventional heddles, but, in a special case, also guide eyes, which are attached directly to the pull and push rods, affords, a simple embodiment of the invention.
An advantageous embodiment is proposed with a drive of the heddles by cords as force transmission elements which are connected to the electric motors, the fan-like or register-like arrangement being made possible by means of deflecting rollers or, in a further advantageous refinement, by means of deflecting levers with a stroke step-up. The deflecting rollers or deflecting levers in this case deflect the cords preferably through 60° to 120°, most preferably through 75° to 105°, in order to provide as much space as possible for register-like fanning out. If two springs are used in this case, for example, one of the springs may be arranged on the side of the heddles which lies opposite the deflecting rollers or deflecting levers and be designed as a conventional tension spring.
The kinetic energy of the heddles may be made available predominantly by springs. The springs are in this case set up such that they make available in a first end position and in a second end position in each case high potential energy as force which drives the heddles in the direction of the other end position. In one position, in a solution with a spiral compression spring, the spring force disappears. In a solution with a compression spring and tension spring or a solution with two opposite tension springs, the potential energies of the two springs cancel one another. During movement, therefore, in a position which is advantageously the middle position, the heddles have a maximum speed. The heddles are then moved further on into the other end position in each case, the springs then being capable of absorbing the kinetic energy of the heddles in the form of potential energy. In order to allow controlled movement and selective dwelling in the first or the second end position, for the first end position and for the second end position in each case holding means are provided which stop the movement and hold the respective heddle in the end position assumed. In order to allow controlled movement, then, a selectively switchable electric motor is additionally provided. This, together with the spring force, overcomes the holding force of the holding means and can thus free the heddle from its holding position. Basically, therefore, the motor is intended for releasing the holding means and for initiating the movement action. Furthermore, the motor serves for compensating energy losses and for adapting the device to changing operating conditions. The device is controlled by means of the control of the motor.
It is advantageous if at least 75% of the kinetic energy is extracted from the spring or springs and the electric motor applies at most 25% of the kinetic energy. Furthermore, it is advantageous if the holding means are designed, uncontrolled, as permanent magnets which cooperate with magnetic stays, the ends of the step-up lever serving as magnetic stays. Advantageously, in a third shed position between the upper shed and the lower shed position, no force is exerted on the heddles. In a symmetrical arrangement, this is a middle shed position.
The abovementioned elements to be used according to the invention, and also those claimed and those described in the following exemplary embodiments, are not subject to any special exceptional conditions in terms of their size, shape, use of material and technical design, and therefore the selection criteria known in the respective field of use can be adopted unrestrictively.
In particular, the invention is not restricted to a textile weaving machine having individual heddle movement. On the contrary, the invention may also be used for a weaving machine in which heddles are combined, for example by means of heddle shafts, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of a device for textile machines, in particular a textile weaving machine having individual heddle movement, are described in more detail below with reference to the drawings in which:
FIG. 1 shows a heddle drive according to a first exemplary embodiment of the invention with pull and push rods, accumulator spring and torque motor;
FIG. 2 shows an illustration of the torque motor according to FIG. 1 as a detail;
FIG. 3 shows a force graph for the movement sequences of the warp threads;
FIG. 4 shows a heddle drive according to a second exemplary embodiment of the invention with tension spring, spiral spring, cord elements and torque motor;
FIG. 5 shows an illustration of the torque motor according to FIG. 1 as a detail;
FIG. 6 shows a heddle drive according to a third exemplary embodiment of the invention with tension springs, cord elements and linear motor; and
FIG. 7 shows an illustration of the linear motor of FIG. 6 as a detail.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first exemplary embodiment for carrying out the present invention is illustrated in FIGS. 1 and 2 .
FIG. 1 shows a device for driving the heddles 4 , designed as driving parts of the warp threads 2 , of a textile weaving machine having individual heddle movement, in a side view. The warp threads 2 are moved by means of the heddles 4 having thread eyes 3 , such that, as illustrated in the exemplary embodiment, they are located either in an upper shed position or in a lower shed position. The heddles 4 are arranged by means of couplings 36 on push and pull rods 30 which in each case have a length different from that of the adjacent rod. The drive elements for the heddles 4 can thereby be arranged in a staggered or register-like manner. The staggered or register-like arrangement is provided here in duplicate form, in such a way that the left half of the heddles 4 is assigned to a left register of electric motors 32 and the elements assigned to these, while the right half of the heddles 4 is assigned to a right register of electric motors 32 , virtually in a mirror-symmetrical arrangement, and the elements assigned to these. The ends of the push and pull rods 30 are in each case fastened to an operative lever 28 which is operatively connected to an electric motor 32 designed as a pivoting motor. Each electric motor 32 has a coil 6 which is fastened to a coil carrier 20 pivotable about an axis 19 . The coil former, in turn, is arranged between two base plates 18 . Each electric motor 32 has, furthermore, a permanent-magnetic plate 16 . Thus, by means of the polarity of a current flowing through the respective coil, the coils assume one of two end positions which are marked in the drawing. These two positions correspond to the two positions “upper shed” or “lower shed” of the heddles 4 and consequently the shedding of the warp threads 2 .
However, the position of the abovementioned elements is not free, but is prestressed by a spiral tension and compression spring 8 such that, in the two end positions “upper shed” and “lower shed”, a spring force directed away from the stops takes effect, while in a middle position of the coils 6 , no spring force takes effect. Two stop magnets 26 are arranged such that they form holding means for the two end positions “upper shed” and “lower shed”.
The graph 3 shows the force conditions of the elements described above. In this case, the spring force graph 100 shows that the spring force of the spiral tension and compression spring 8 is symmetrical about the middle position, in which it disappears, and is linear. During a raising or lowering movement of the heddles 4 , the largest fraction of energy is applied by the spring drive of the spiral tension and compression spring 8 . However, the movement is initiated by an electric motor 32 . As long as the electric motor 32 is not in operation, the corresponding heddle 4 is retained by the upper or the lower stop magnet 26 in the upper or lower end position, which correspond to the upper shed position or the lower shed position of the warp threads of a shed. This is achieved in that the stop magnets 26 designed as permanent magnets have a higher holding force 102 than the restoring force of the spiral tension and compression spring 8 during deflection in the end positions. It should be pointed out that the holding force of the stop magnets 26 has a short range and is therefore relevant at all only in the vicinity of the levers 28 and therefore only in or in the vicinity of the respective end position.
In order, then, to set the heddles 4 in motion, that is to say to initiate a movement from the upper to the lower end position or from the lower to the upper end position, the corresponding coils 6 are supplied with voltage and the electric motors 32 is thus put into operation. The sum of the active forces 104 of the electric motor and of the spring force 100 of the spiral tension and compression spring 8 in a deflective state, that is to say in one of the end positions, is greater than the holding force 102 of the corresponding stop magnets 26 .
If, then, the holding force of the stop magnets 26 is overcome, the movement of the heddle via the corresponding push and pull rod 30 is brought about predominantly by the spring force of the spiral tension and compression spring 8 , the electric motor 32 cooperating in this movement, without appreciably contributing to it. When the other end position is reached, that is to say, for example, the lever 28 comes into the active range of the lower stop magnet 26 , the new end position is reached and the spiral tension and compression spring 8 remains deflected, since, in this position, the force of the permanent magnet 26 is higher than the restoring force of the spiral tension and compression spring 8 and the electric motor 32 does not assist the latter.
In the exemplary embodiment shown here, the spiral tension and compression spring 8 is operated in the linear range, so that the spring force graph 100 can be represented by a straight line. The spring force is assisted only insignificantly by the warp thread force 106 , and therefore the warp thread force 106 plays no part here. The stop magnet graph 102 clearly shows the short range of the magnetic forces which act only when the levers 28 are in the immediate vicinity of the stop magnets 26 and an end position is assumed. The coil force graph 104 of the electric motor 32 has, in the operating mode described here, a constant force which may point in one direction or the other, depending on polarity.
In the exemplary embodiment described here, the electric motor 32 is designed such that, in addition to the upper position and the lower position, a middle position of the heddle 4 can be assumed and the heddle 4 can be moved out of this middle position into the upper position or into the lower position. The purpose of this operating mode is that a position of rest can be assumed in which the spiral tension and compression spring 8 exerts no force on the push and pull rod 30 and the corresponding heddle 4 . The heddle 4 is controlled solely by means of the electric motor 32 which, for this purpose, is connected to a control unit of a weaving machine in a way not illustrated in any more detail.
FIG. 4 and FIG. 5 illustrate a device for driving the heddles of a textile weaving machine having individual heddle movement, in a side view, according to a second exemplary embodiment.
In this exemplary embodiment, wire cords 24 serve as pull elements. The wire cords 24 are connected to the heddles 4 in a conventional way, for example by means of couplings, and in each case have a length different from that of the adjacent cord. As a result, the drive elements can, in turn, be arranged in a staggered or register-like manner. Here, too, the staggered or register-like arrangement is provided in duplicate form in such a way that the left half of the wires cords 4 is assigned to an upper register of electric motors 32 likewise designed as a pivoting motor and the elements assigned to these, while the right half of the wire cords 24 is assigned to a lower register of electric motors 32 and the elements assigned to these. The ends of the wire cords 24 are in this case likewise fastened to an operative lever 28 which is operatively connected to an electric motor 32 . The electric motor has basically the same set-up as in the first exemplary embodiment.
In this exemplary embodiment, the heddles 4 are prestressed, on the side facing away from the electric motor, in the lower shed position in each case by means of a tension spring 12 . In this exemplary embodiment, the spring force counter to the tension spring 12 is brought about by spiral springs 10 which are arranged on the electric motor 32 . In this case, the forces of the tension spring 12 and of the spiral spring 10 cancel one another in a middle position of the coils 6 . Two stop magnets 26 are arranged, in turn, such that they form holding means for the two end positions “upper shed” and “lower shed”. The conditions are otherwise identical to or correspond to the first exemplary embodiment.
FIG. 6 and FIG. 7 illustrate a device for driving the heddles of a textile weaving machine having individual heddle movement, in a side view, according to a third exemplary embodiment.
In this exemplary embodiment, the wire cords 24 likewise serve as pull elements for the heddles. The wire cords 24 again have in each case a length which is different from that of the adjacent cord. As a result, the drive elements can again be arranged in a staggered or register-like manner. Here, too, however, the staggered or register-like arrangement is provided in a simple way.
The ends of the wire cords 24 are fastened about an axis to a pivotable operative lever 22 which is operatively connected to an electric motor 34 .
The difference from the second exemplary embodiment is here, in particular, that the cord deflection is not formed by deflecting rollers, but by an operative lever 22 which is pivotable about the axis and which is coupled by means of a to the electric motor 34 . The electric motor 34 is designed here as a linear motor. In this exemplary embodiment, the wire cords 24 are prestressed by two tension springs 12 such that in each case the spring force of a tension spring 12 takes effect in the two end positions “upper shed” and “lower shed”. In this case, the forces of the tension springs 12 cancel one another in a middle position of the coils 6 of the electric motor 34 . Two stop magnets 26 are again arranged such that they form holding means for the two end positions “upper shed” and “lower shed”. The conditions are otherwise identical to or correspond to the first exemplary embodiment.
It should be emphasized for clarity that, in the description of the invention and particularly in the description of the preferred exemplary embodiments, a distinction was made between the heddles 4 and the force transmission elements 24 and 30 . However, the push and pressure rods 30 may also be continuous and therefore also form the heddles. Furthermore, the cords 24 may also have eyes for leading through the warp threads and consequently at the same time form the heddles.
LIST OF REFERENCE SYMBOLS
2 Warp threads
3 Thread eye
4 Heddles with thread eye
6 Coil
8 Spiral tension and compression spring
10 Spiral compression spring
12 Tension spring
14 Deflecting roller
16 Permanent-magnetic plate
18 Base plate
19 Axis
20 Coil carrier
22 Cord deflection with reduction to linear drive
24 Wire cord, pull element
26 Stop magnets
28 Lever
30 Push and pull rods
32 Electric motor, torque motor
34 Electric motor, linear motor
36 Coupling
100 Spring force graph
102 Stop magnet graph
104 Coil force graph
106 Warp thread graph | In order to solve the problem of not having enough space available for a large number of components and keeping the deflection of the electric motor small in a device for controlling the transverse movement of the warp threads of a textile weaving machine, particularly a textile weaving machine with single strand movements, the invention proposes to operatively connect the strands via power transmission elements having different lengths in a staggered or register-like way to an electric motor and to provide the electric motors with a ratio in relation to the strands such that the movement of the electric motors brings about a greater movement of the strands. | 3 |
BACKGROUND OF THE INVENTION
The invention relates to electrolytic separation of metals from solutions, and in particular relates to improvements in apparatus for performing such separation.
PRIOR ART
Electrolytic recovery of silver from photographic or radiographic film processing solutions and other metallic ionized elements from different solutions such as plating solutions is known. A generally known class of device for recovering silver from processing solutions employs a cylindrical chamber through which processing fluid is conducted for electrolytic treatment. A cathode formed by or disposed adjacent and essentially coextensive with the cylindrical wall of the chamber receives silver from the processing solution by electrolytic action. An anode is disposed at or adjacent the axis of the cylinder. Processing solution is circulated through the chamber while electric current is established between the electrodes through the solution.
In prior art devices, circumferential currents of solution typically are induced by stationary nozzles such as shown in U.S. Pat. Nos. 4,028,212 to Bowen et al. and 4,149,954 to Ransbottem, for example, or rotating impellers such as shown in U.S. Pat. No. 3,694,341 to Luck, Jr. As shown in the mentioned U.S. Pat. No. 4,028,212, for instance, a cathode has been formed of flexible stainless steel sheet stock rolled into a cylinder and unrolled or otherwise flexed to separate it from an accumulation of deposited silver. It is also known from U.S. Pat. No. 3,953,313 to Levenson and from my U.S. Pat. No. 4,175,026, for example, to employ carbon filaments or carbon coatings in the construction of cathodes.
SUMMARY OF THE INVENTION
The invention provides an improved device for collecting metallic material from solutions with increased efficiency of operation and greater convenience to the user. In accordance with one aspect of the invention, there is provided a novel impeller/turbulator unit which, besides serving a primary function of pumping solution through the collector chamber, serves the important function of inducing turbulent flow of solution in the collector chamber. This turbulent flow of solution greatly improves the efficiency of the electrolysis action. As disclosed, the collector chamber is cylindrical in form and the impeller/turbulator comprises a rotor disc that is driven in rotation about the axis of the chamber. The disc includes a plurality of radially extending channels which establish centrifugal flow in the solution. The channels of the impeller/turbulator include passages that induce a high degree of turbulence by developing local axial currents which are in counterflow relation to a main axial flow of solution to the collector chamber. An additional effect contributing to turbulent flow in the collector chamber is the action of the impeller/turbulator that angularly sweeps obliquely directed currents through stationary, radial paths of inflow currents.
Another aspect of the invention involves a disposable cathode element formed of carbon-filled plastic sheet material. As disclosed, the cathode is provided as a rectangular sheet that is dimensioned to be curled into a single layer liner on the inner wall of a hollow, cylindrical housing forming the collector chamber. The flexible but resilient character of the cathode sheet permits it to be readily positioned in the collector chamber of the housing with minimal effort, skill, and time, and therefore with a high degree of convenience. The construction of the cathode sheet, moreover, in terms of the cost of raw sheet stock and the fabrication of individual finished sheets, is of such low value as to make it practical to treat the cathode as disposable after one period of use. Disposal of the cathode sheet frees the operator/user of the collector device from the task of cleaning it of collected material and simplifies the steps required of the operator to recharge the unit with a clean cathode. Removal of the cathode sheet from the collected or recovered material electrolytically deposited thereon can be performed at a location remote from the point of use of the collector device. In fact, the cleaning step can be altogether eliminated where the collected metal is smelted, since the cathode sheet will simply burn off the collected metal. Segregating or eliminating the process of stripping the cathode of material collected on it can lead to a reduction in loss or waste of collected material, which can be quite important where this material is silver or other precious metal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal, cross-sectional view of a metal collector device constructed in accordance with the invention;
FIG. 2 is a front end view of the collector device, taken at the lines 2--2 in FIG. 1;
FIG. 3 is a transverse, cross-sectional view of the collector device, taken on the lines 3--3 in FIG. 1;
FIG. 4 is a transverse, cross-sectional view of the collector device, taken along the lines 4--4 in FIG. 1;
FIG. 5 is a perspective view of the collector device, with certain parts in exploded relation to illustrate details of its assembly;
FIG. 6 is a perspective view of an impeller/turbulator element of the invention; and
FIG. 7 is a diagrammatic illustration of the currents induced by the impeller/turbulator.
DESCRIPTION OF THE PREFERRED EMBODIMENT
There is shown a device 10 for collecting silver or other ionized metals in photographic, radiographic, or like liquid solutions. The device 10 includes a liquidtight collector chamber or cell 11 disposed within a hollow, cylindrical housing 12. An interior, cylindrical surface 13 of the housing 12 forms the circumferential boundary of the collector chamber 11. By way of example, the illustrated chamber 11 has a nominal length of approximately 7.25 inches and a diameter of approximately 5.7 inches. At its inner end, the chamber 11 is bounded by a transverse wall 14 permanently sealed to interior surfaces of the housing 12. A cylindrical pocket 16 concentric with the axis of the housing 12 is open to the collector chamber 11. The pocket 16 is provided by a cup 17 sealed at the edges of its mouth to a counterbored aperture 18 in the end wall 14. At the center of a base 19 of the cup 17, a blind bore 20 provides a seat for a spindle shaft 21.
Partially disposed in the pocket 16 is a hub assembly 26 of an impeller/turbulator 27. A rotor 28 of the impeller/turbulator 27 (FIG. 6) has a center hub section 29 and an annular disc section 30 axially and radially outward of this hub section. The plane of the hub 29 is offset from the disc 30 to provide a central recess 31. The plane of the disc 30 extends transversely to the chamber axis, and is spaced with a gap from the chamber end wall 14. An outer face 36 of the impeller/turbulator rotor disc 30 has a plurality of angularly spaced, open-faced slot channels 37 extending radially between its inner and outer diameter. At angular locations intervening the open channels 37, there are formed in the rotor disc 30 closed boundary channels 38 extending both radially and axially with respect to the chamber axis. These latter channels 38 have inlet openings on the inner side of the disc 30 adjacent the hub 29 and outlet openings on the outer face of the disc remote from the hub 29. In the disclosed arrangement, the closed boundary channels 38 are cylindrical and have their individual axes lying in a common imaginary cone forming an oblique angle with the plane of the rotor disc 30. The impeller/turbulator hub 29 is permanently attached by gluing or other suitable means to the remainder of the hub assembly 26, which is assembled in the cup pocket 16. The hub assembly 26 is permanently magnetized so that it is magnetically coupled with a cup-shaped driver 41, also permanently magnetized, and telescoped over the housing pocket cup 17.
A skirt section 46 of the housing 12 extending axially beyond the collector chamber 11 receives and supports an end wall 47. An electric motor 48 is mounted on the end wall 47 by screws 49. An output shaft 51 of the motor 48 projecting into the space of the skirt 46 is received in an inner end of the magnetic driver 41 and supports the driver in rotation about the axis of the chamber 11.
The outer end of the housing chamber 11 is closed by a removable end plate or cover 56. The end plate 56 is generally circular in form, having a diameter substantially equal to the outside diameter of the housing 12. The end plate cover 56 is releasably retained on the housing 12 by a clamp ring 57 of known construction and operation, which seats in circumferential grooves in the housing and cover.
An inlet hose coupling 58 extending radially with respect to the end closure 56, a radial passage 59 in the closure, and a central axial passage 60 in the body of the closure are serially interconnected to form an inlet flow path for solution into the chamber 11. Similarly, a hose coupling 61, a transverse passage 62, and an axial passage 63 are serially interconnected to form an outlet for solution from the chamber 11. Journaled in a cross bore 64 intercepting the inlet and outlet passages 60,62 is a cock 65 having double ports individually aligned with these passages. An external handle 71 is manually pivoted from the illustrated open position, where the cock ports are aligned with the passages 60,62 through 90 degrees to a closed position where the ports are perpendicular to these passages. The axial outlet passage 63 opens directly into the outer end of the chamber 11 near its wall 13, while the inlet passage 60 is coupled with a central anode tube 73. The anode tube 73, preferably of stainless steel or other noncorrosive, electrically conductive material, is retained on the closure plate 56 by a threaded stem 74 of like material welded or otherwise secured to it. The threaded stem 74 extends through a suitable bore in the closure plate 56 and is retained by a threaded nut 75. A gasket 76 prevents leakage along the stem bore. Inlet flow of liquid entering through the coupling 58 is axially conducted by the anode 73 centrally through substantially the full length of the chamber 11. A hollow, cylindrical cap 81, pressed or otherwise retained on the inner or free end of the anode 73, has a plurality of outlets 82 in the form of radially extending, cylindrical holes 83. A lower end face of the nozzle or cap 81 is provided with a small central bore 86 for journaling an outer end of the spindle shaft 21. Thrust washers 87 are provided adjacent opposite ends of the spindle shaft, and are adapted to bear against opposed ends of the rotor and hub assembly units 28,26.
A screw 89 of stainless steel or other noncorrosive material in a threaded bore through the end closure plate 56 and an associated hose coupling 90 provide a bleed port for releasing air from the chamber 11 to initially charge it with liquid solution. The housing 12, end wall 14, cup 17, end closure 56, nozzle 81, and couplings 58,61,90 are formed of suitable corrosion-resistant, plastic material such as polyvinyl chloride.
In accordance with the invention, there is disposed in the chamber 11 a cathode sheet 96 which forms a replaceable liner for the cylindrical chamber wall 13. The cathode sheet 96, ideally, is a flexible, originally flat sheet of polyvinyl chloride filled with carbon. The carbon is uniformly dispersed through the body of the sheet, and is sufficiently high in content to render the sheet 96 electrically conductive and place it in a class of materials known as directly platable plastics. For example, the sheet can have a relatively low bulk resistivity of approximately 7 ohms. The sheet typically can have a thickness of 0.0625 inch, for example.
As suggested in FIG. 5, the originally flat, imperforate cathode sheet 96 is flexed into a cylinder and, with the end closure 56 removed, is inserted into the chamber 11. The transverse dimensions, i.e., the length and width of the cathode sheet 96, generally correspond to the circumference and axial length of the interior surface 13 so that when the cathode sheet is inserted in the chamber 11, it forms a single layer through substantially the full length of the chamber 11. The natural resiliency of the polyvinyl chloride forming the cathode 96 is operative to expand it into a snug fit against the chamber wall 13. A threaded stud 98 of stainless steel or other electrically conductive, corrosion-resistant material is threaded into a threaded hole through the side of the housing 12. An end 99 of the stud 98 projects into the chamber to assure that it is in direct electrical contact with the cathode sheet 96.
In operation of the device 10 to collect ionized metal from a liquid solution, a storage tank, process tank, system piping, or other like reservoir of such solution is suitably connected to the inlet and outlet hose couplings 58, 61. With the cock 65 open and motor 48 operating, the collector device 10 is self-pumping by virtue of the action of the impeller/turbulator 27. It will be understood that during operation of the device, a suitable electrical power supply is connected across the anode and cathode terminals formed by the threaded stem 74 and threaded stud 98.
Net flow through the collector chamber 11 involves central axial flow of incoming liquid through the anode 73 and tangential outflow through the axial passage 63. This net flow is induced through the chamber 11 by operation of the impeller/turbulator 27. More particularly, fluid in the immediate vicinity of the rotor 28 is continuously driven by centrifugal force from the central areas of the rotor disc 30 to the outer peripheral areas of the disc. Radial flow from the nozzle holes 82 is primarily induced by the open-faced channels 37 in the rotor disc 30. The radial flow draws fluid from the nozzle holes 82 and forces it outwardly towards the wall 13 of the chamber 11. Rotation of the disc 30 also causes the liquid solution to swirl in the same direction. It is presently believed, from the foregoing analysis, that flow currents can be considered to be generally helical along the chamber wall 13 axially outward from the impeller/turbulator 27 to the outlet 63 in the closure plate 56.
An important feature of the impeller/turbulator 27 is its ability to generate a high turbulence and eddies which greatly increase the deposition rate of metal ions on the cathode 96. The turbulence and eddies are believed to be the result of the action of the oblique closed boundary rotor channels 38, which draws in liquid on the inner face of the disc 30 at its generally central regions and expels currents on the outer periphery of its outer face. Inspection of FIG. 7 reveals that the axes of the closed boundary rotor passages 38 intersect the plane of the axes of the radial nozzle holes 82. Thus, the currents of liquid expelled from the rotary disc passages or channels 38 sweep through the stationarily located streams issuing from the nozzle holes 82. This sweeping action is believed to induce a pulsation of the currents in the chamber 11, which results in excessively high levels of turbulence that advantageously improve the deposition rate of ionized metal on the cathode 96.
When a sufficiently heavy coating of metal has been deposited on the cathode 96, the end closure 56 is disassembled from the housing 12 and the cathode 96 and metal deposit on it are removed from the chamber 11. A new sheet of cathode material is positioned in the chamber 11 and the collection process can be resumed.
The disclosed cathode material is relatively inexpensive and can be considered to be disposable. When used as a disposable element, the cathode sheet makes use of the device 10 highly convenient for the operator. There is no need, for example, for the operator to strip the cathode and collected metal apart. The cathode and collected metal can be shipped to a metal smelter for full credit without the possibility of loss of material which could occur where an operator attempted to scrape or otherwise clean the metal from the cathode. The smelting operation simply burns off the cathode, thereby eliminating the need for labor in cleaning the cathode.
It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited. | A device for collecting ionized metal from a liquid solution, such as silver from photographic or radiographic solutions, which is highly efficient in operation and convenient in use. Efficiency of the device results from a unique impeller/turbulator which, besides being adapted to pump liquid through the device, induces a relatively high state of turbulence in such flow that promotes electrolytic action. A cathode on which metal ions are deposited is formed of a flexible sheet of carbon-filled plastic that is low enough in cost to be conveniently disposable. | 2 |
BACKGROUND OF THE INVENTION
The invention relates to a method for producing an adhesion-mediating coating on the surface of workpieces, preferably those of headlight reflectors made of plastic, having a vacuum tank in which the workpieces are exposed to a plasma coating process, with inlet and outlet openings in the tank, by which a process atmosphere determining the plasma coating process can be produced, during a controlled inlet and outlet of substances.
From DE-A 40 10 663, an apparatus and method are known for the production of coatings on the surface of workpieces, preferably headlight reflectors made of plastic. It involves especially a special surface treatment of three-dimensional substrate surfaces, the object being to achieve a corrosion-resistant and nonsmearing mirror surface.
What is involved is a PCVD coating process with a microwave-ECR plasma coating source and a so-called rotary cage situated in the vacuum chamber and carrying the substrates past the coating source in a planetary motion controlled by frequency and phasing.
The coating process provides a plurality of process steps which first modify the substrate on its surface within the scope of a noncoating plasma pretreatment so that functional groups will form on it, such as hydroxyl-carbonyl or amino groups. After that, for improved adhesion mediation, a coating formed from a SiC or SiCO gas atmosphere is deposited onto the substrate surface. This is followed by the application of an aluminum coating to the substrate. In a final step, a protective coating of the same coating composition as the above-described adhesion mediating layer is applied to the metallized substrate to increase its resistance to corrosion and smearing.
Further testing has shown, however, that many substrate materials, such as plastics and varnishes, undergo irreversible damage to the substrate surface under the process conditions described in DE-A 40 10 663 This is especially true of the first monolayers of plastic substrates, where damage is caused by ultraviolet rays occurring in the plasma and by collision of high-energy plasma particles with the substrate surface. Such disadvantageous interactions with the substrate surface depend on the types of particles included, and on the distance between substrate and plasma, as well as on the prevailing particle partial pressures.
SUMMARY OF THE INVENTION
According to the invention the workpieces are exposed to a plasma coating process in a tank, with inlet and outlet openings, by which a process atmosphere determining the plasma coating process is controlled so that the above-mentioned surface damage to the substrates will be avoided and an adhesion-mediating coating will be produced which will be chemically compatible with most known plastics and varnishes. Furthermore, the process times and costs necessary for such production are reduced.
According to the invention, the process gas atmosphere consists essentially of organosiloxanes and inert gas or of pure silane or of silane plus inert gas.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The basic idea essential to the invention is the application of an adhesion-promoting coating to a substrate as an intermediate coating. Such coatings are also frequently called "precoats." Furthermore, the coating can be applied to coatings already present on the workpiece as a coating for protection against external corrosive influences, such as aggressive media.
For the production of such coatings on workpieces, plasma-enhanced vacuum processes are preferably used. Other known coating processes, however, can also be performed.
At low process gas pressures within the process chamber the plasma-enhanced coating of plastic surfaces often results in damage to the plastic surface due to the plasma radiation, as already mentioned. The consequence is a poorly adherent coating, especially under the influence of the corrosive medium. To achieve a sufficiently uniform coating of three-dimensional workpieces, however, the coating particles must be provided with a great average free trajectory in the processing atmosphere. This, as a rule, is achieved only at low process pressures.
The process according to the invention, by the admixture of a monomer, e.g., an organic silicon compound or silane with a noble gas such as helium, as a collision partner, makes it possible to coat three-dimensional workpieces even at pressures of several Pascals, and at distances of the workpiece from the plasma source of more than 10 centimeters.
Upon mixing the process gas, such as tetramethyldisiloxane, with a noble gas such as helium as the carrier gas, it was discovered that damage to the substrate surface is surprisingly nonexistent. Experiments likewise showed that even pure silane as the process gas atmosphere eliminates damage to the coating.
As a common method of testing the adherence of coatings to workpieces, the well-known caustic soda solution test, also called the Fiat standard test, is used. Metal coatings adhering but poorly to the workpiece surface quickly dissolve in the solution. Experiments showed that, with the adhesion-mediating coating deposited according to the invention, additional coating deposits survive the caustic soda solution test in lasting adherence to the substrate.
As previously mentioned, a plasma-enhanced CVD process is used which operates with process pressures within the vacuum tank between 0.01 Pa and 100 Pa. Preferably, microwave input into the plasma area within the process chamber is used.
The microwave power input for the production of plasma and plasma maintenance amounts to between 1 kW and 50 kW per cubic meter of plasma volume.
The process gas mass flow necessary for plasma stability is between 50 and 23000 hPa*l/min per cubic meter of plasma volume. The suction capacity of the pumps regulating the outflow of material is between 400 and 40000 l/sec of nitrogen per cubic meter of plasma volume.
With the method described, both continuous coatings with thickness greater than 100 Å and coatings with thicknesses under 20 Å that do not completely cover the substrate surface can be made. Both types of coating result in adhesion-promoting coatings in the stated manner.
In the case last mentioned, what is involved is less a coating in the literal sense than it is a surface modification.
The extremely slight coating thicknesses furthermore permit very short processing time, which in the case of statistical coating can amount to less than one second. The method according to the invention is thus quicker than those known in the state of the art; such a great reduction of processing time results in a considerable reduction of manufacturing costs.
Following the application of the adhesion promoting coating, a reflective layer of aluminum or other metal of from 700 A to 1 μm is applied. The metal layer can be applied by either a vapor deposition process, as disclosed in U.S. Pat. No. 4,956,196 (incorporated herein by reference), or by a sputtering process.
For workpieces having complex three dimensional surfaces, a sputtering gas pressure of over 6 μmbar using a heavy inert gas such as krypton is preferred.
Following application of the reflective coating, it is preferable to apply a protective coating of the same composition as the adhesion promoting coating, according to the same method.
The foregoing is exemplary and not intended to limit the scope of the claims which follow. | A process gas atmosphere consisting essentially of (a) organosiloxanes and inert gas, or (b) pure silane or (c) silane plus inert gas is introduced into a vacuum chamber and exposed to microwaves to produce an electro-cyclotron resonance in a plasma for coating substrates. The process is useful for producing an adherent coating on a plastic substrate, especially an intermediate coating for a reflective coating in an automotive headlamp. | 2 |
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a transportation unit, such as a wagon and/or train, with at least one plate-shaped alignment unit, which can rotate about a vertical axis, for taking a vehicle from a ramp and aligning it, the length of which vehicle exceeds a usable width of the transportation unit, but the width of which vehicle does not project beyond said transportation unit.
Such a transportation unit is known from DE 10258405 A1. Its plate-shaped alignment unit has wheels at the bottom side, by means of which it is moved on the wagon floor and the ramp when it is rotated. During this movement the gap between the wagon floor and the ramp has to be bridged. For this purpose, the alignment unit is pulled out in sections, which are guided in such a way that they slide against each other, while the wheels are lifted off. This lifting and sliding structure requires a bearing at the center of motion with the capacity to support a large load, resulting in significant weight and height.
BRIEF SUMMARY OF THE INVENTION
It is an object of the invention to create a low-profile, simpler transportation unit, which can easily be accessed by the vehicle that is to be transported.
The object is achieved in that the alignment unit is mounted on the floor of the transportation unit so as to rotate on a carrier track, and the transportation unit is fitted with flaps, which can pivot onto the ramp or ramps respectively, and onto which the carrier tracks extend, which as a result also supports the alignment unit in this area, when it is rotated and partially projecting.
Advantageous embodiments are specified in the dependent claims.
By using side flaps of a transportation unit for the loading process, various advantageous features are obtained:
1. The alignment unit has a larger surface during the loading operations. This way, goods which are longer than the width of a transportation unit in its running state, can be positioned more easily. 2. The flaps have the function of bridging the gap between the transportation unit and a ramp. 3. A carrier track for the alignment unit is mounted in the side flaps/loading flaps.
When the side flaps are opened, the mobile parts of the side flaps and the base of the transportation unit form a larger mobile surface. This mobile unit allows to move/turn material located on its surface in the desired direction. Since this surface is wider than the transportation unit, longer items can be loaded without problems. For the train to be ready to start, the side flaps are closed along with the moving parts, which are now treated in their additional function as a part of a side flap. The alignment unit is fixed when the side flaps are closed.
It is possible to use alignment units in multi-level loading units, if appropriate multi-level ramps are available. As the train always stops in the same position, columns for the upper ramp can be set up where there are no flaps.
Individual special wagons (toilets, stairs, shopping etc.) are coupled in between in some places.
For moving the alignment unit, an engine is mounted at the fixed base or body underneath the floor, which allows a continuous circular movement of the alignment unit in both directions, preferably by means of a toothed ring, which is mounted below the alignment unit. An electric control that is connected to the engine serves to control the alignment unit from any place inside or outside of the train, for example by remote control. The alignment unit is integrated in the floor and the side walls of a transportation unit, and the floor and the side walls can partly be replaced by it. The alignment unit is located on carrier tracks which are fixed on the floor/the body and the flaps. The carrier tracks are circular. The alignment unit can be turned on the tracks, either sliding or by means of rollers. The alignment unit is enclosed by a surrounding ring, so that it always remains in contact with the carrier track in the case of shocks or other vertical movements. A protective sleeve that is mounted above it keeps dirt away.
The alignment unit can be added to an existing vehicle. The alignment unit can consist of one piece, if it is flexible enough in the appropriate regions, for example because of thinner or different material, so that it can be moved with the side walls.
The way the alignment unit is set up ensures that it is flat at all times during the loading process, and that there are no breaks in the form of gaps or holes within the entire area of the transportation unit with its side flaps open, thereby contributing significantly to safety.
The side flaps are opened and closed by mechanisms located in the side walls. For example, a nut block guided in a rail is moved up and down with a threaded rod by means of a rotating drive, the nut block is connected to the flap by a rod, so the flaps open and close. When the lower flap is open, the block, together with the rod, can be lowered to a floor level. Inside of the flap, the rod can be advanced further, and engages only when the nut block has reached a certain height. The end of the rod is T-shaped and engages in specially shaped hooks inside the flap. Their shape is such that the T-shaped end unlatches only when the flaps are open. The rods are sunk in recesses/openings in the flaps, so they are protected, and flatness is ensured.
Alternatively, a telescopic rod is mounted between the nut block and the flap. Instead of unlatching, it is telescoped and this way is recessed in the flap. A spring that is integrated in the rod keeps it at its respectively possible length.
Alternatively, a multistage hydraulic cylinder is used, which is placed between the flap and a place in the side wall. It can not be recessed but can be covered. A threaded rod is obsolete.
Besides the lower flaps which can be pivoted onto the ramp, upper flaps are advantageously placed at the roof edge or at a middle plate. These flaps are equipped with pivot devices similar to those at the lower flaps. They can be operated with the same threaded rod with an inverse thread. A drive moves the two superposed flaps simultaneously. When the upper flaps are open, the rod is not recessed.
The closing edges/areas of the upper and lower flaps are advantageously trapezoidal. After they are latched by means of bolts, whereby the locking edges are held against each other, they are stabilized, secure and isolate against external influences.
The bolts lock after the flaps have been closed by the closing-opening mechanism.
A flap for driving on and off is advantageously hinged on the lower flap and is supported by springs that are attached underneath, so it is pressed against the upper flap or against the ramp or in a desired angular position.
Advantageously, a driver is in the car during the entire loading process and positioning aids help him to drive on and off in the correct way. Display panels are integrated in the upper flaps, which are preferably swung out or extended when the flaps are open and which serve as traffic lights and visual aids for driving on and off.
Markings on the alignment unit indicate the correct parking position. Pressure sensors located between the markings in the floor or optical or electromagnetic sensors, together with the display panel serve as positioning aids.
Traffic lights and/or display panels, signaling to vehicles driving on or off are mounted in fixed wall segments next to the flaps at the outside and inside of the train.
An articulated train has one mobile unit per segment, section or wagon (in double-deck trains: two superimposed mobile units). As the segments are short, the width may be correspondingly large, in accordance with the clearance gauge.
The body of the train is lowered and the wheel case, which encloses the wheels with axle, drive, suspension, brake and coupling, is located partly above the level of the base plate. Due to the width of the train, there is room between the walls and the wheel cases. The level of the base plate can be continued into the next section of the train without obstacles, so that persons can walk here.
The axle is supported by two vertically mobile blocks with axle bearings, which are attached to the body by a hinge. Springs/shock absorbers are placed between block and wheel case as a suspension. The wheel cases are stable and take the spring load.
Hydraulic cylinders are fitted between the blocks and the wheel cases to ensure that the train does not vibrate during the loading process and that it is aligned to the height of the ramp. Ramp sensors control the hydraulic cylinders, enabling an automatic level adjustment.
An engine for driving the wheels is mounted to the block, and drives them via the axle. The train can be stopped either with the motor reversed to function as a dynamo, as a means of energy recovery, and/or with a brake.
By incorporating the side walls of a transportation unit, for example of a train, in the loading process, it is possible, due to the thus obtained greater maneuvering surface, to load any kind of goods, in particular goods with a length exceeding the width of the transportation unit, in a simple manner, very quickly, and independently and simultaneously at each loading position of the transportation unit, in particularly advantageous manner. When the side walls are open, supporting and/or mobile parts of the side walls and floor of the transportation unit jointly form a larger mobile alignment platform. This platform allows moving the material located on it in the desired direction. For the train to be ready to start, the side walls are closed along with the supporting and/or mobile parts, which can now be moved with the side walls.
The arrangement can be made in such a way, that the moving parts of the loading unit replace parts of the floor and the side walls.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 Perspective view of a simple transportation unit between ramps.
FIG. 2 Top view of two single-deck alignment units.
FIG. 3 Perspective view of a long transportation unit with alignment unit between ramps.
FIG. 4 Perspective view of a complete articulated train, partly open, partly closed.
FIG. 5 Horizontal section through fixed side wall and flap with swivel mechanism.
FIGS. 6 a - 6 b Front views of various closing-opening mechanisms of the flaps, each in three positions.
FIGS. 6 c - 6 d Front view of a closing-opening mechanism of the flaps hydraulically folded away/up.
FIGS. 7 a - 7 b Vertical section of the closing mechanism of the flaps before and after closing the side walls.
FIG. 8 Vertical section of the swiveled-in display apparatus.
FIG. 9 Top view of a section of the train in loading position, partially opened floor and wheel case.
FIG. 9 a Top view of the body with carrier tracks in loading position.
FIG. 9 b Cross Section of a section of the train; flaps swiveled out.
FIG. 10 Vertical section of the wheel case.
FIG. 11 Cross section of a double-deck train at its loading position between double ramps.
DESCRIPTION OF THE INVENTION
FIG. 1 shows a transportation unit 1 , which is located between two ramps 9 on a track 10 . The drawing shows open lower flaps 2 in the front section of the transportation unit 1 , and closed ones in the rear section. The alignment unit 5 , 5 a at the front is rotated so that a car 11 can drive on and of in a straight line between the ramp and the lines 6 limiting the driveway.
FIG. 2 shows two alignment units 5 , 5 a in detail. The left side of the drawing shows a partly turned position and the right side shows the driving position, in which the lower flaps with two movable wings 5 a can be folded up, due to longitudinal hinges 7 that are aligned at a fixed base plate 4 . On the alignment unit 5 marking lines 6 limit the driveway.
FIG. 3 shows a long form of the alignment unit 12 . The two lower flaps bridge the gap between the transportation unit and the ramps 9 and comprise a carrier track 4 b for the alignment unit 12 .
An example for the utilization of this special form might be shipping a car on a motorail, wherein the length of the car significantly exceeds the width of the train:
For the vehicle to access the train at any point, it has to be brought to a stop in an oblique or transverse orientation and will then be aligned in the longitudinal direction. The fact that the foldable side walls are included in the loading surface, a larger loading area is available for the alignment of the car, so it can be loaded very easily, even though its length exceeds the width of the train in its running state.
The rotational alignment unit 5 , 5 a , 12 is constructed in such a way that once a vehicle is oriented in the longitudinal direction, its parts, namely the carrier track 4 b and the wings 5 a , which are located in the area of the side walls 2 , are folded up with the side walls 2 , so that all these mobile parts 2 , 4 b , 5 b are fixed and the train is ready to start. Said parts 4 b , 5 a become part of the side walls 2 , they partly replace them and contribute to their stabilization.
Even very long items, trucks for example, benefit from a loading process involving the side flaps. In this case, the alignment unit is not shaped as a full circle, the diameter of which would be too large. Instead, as FIG. 3 shows, an elongated shape is chosen, so that the side walls only function to bridge the gap between the ramp and the transportation unit 9 , and also to form an alignment unit 12 . In this version, due to the elongated shape of the alignment unit 12 , the loading floor is not closed at all times.
FIG. 4 shows an overview of a transportation unit, which is designed as a closed articulated train 1 , with opened or closed upper and lower flaps 2 , 3 . Traffic lights and/or display panels 16 are attached outside or inside the train within the fixed walls 8 next to the flaps 2 , 3 . The body and thus the fixed base plate 4 of the transportation unit 1 is preferably lowered, and the wheel case 17 which encloses the wheels with axle, a drive, a suspension, a brake and a coupling, partly projects above its level. Due to the width of the train, there is room between the fixed walls 8 and the wheel case 17 and the lowered floor of the base plate 4 . This floor continues into the next section of the train, so persons can walk here. Furthermore, various technical details are shown, which facilitate and advantageously improve the operation of loading a car. Each detail is particularized in a separate drawing.
FIG. 5 shows an example of a horizontal section through a fixed side wall 8 with a control device for swiveling. The side flaps 2 , 3 are opened and closed by devices located in the fixed side walls 8 . Turning a threaded rod 13 g moves up and down a nut block 13 h that is guided in a rail 13 i , and connected to the flap 2 by a rigid or telescoping rod 13 a , 13 b , 13 c , thereby closing and opening the flap. A bolt 13 d in the locked position, and an engaged surrounding trapezoidal edge 13 e are also shown.
FIG. 6 a - c are side views of the closing-opening mechanism 13 , each with the flaps 2 in three different positions, with different versions of the rods 13 a , 13 b , 13 c.
FIG. 6 a . Inside the flap 2 the rod can move further and catches only in the position 13 a ″ when the nut block 13 h has reached a certain height. The end of the rod 13 a is T-shaped and engages in a specially shaped hook 13 f within the flap 2 . These are shaped in such a way that the T-shaped end unlatches only when the flap 2 is open. The rods 13 a are protected in recesses and/or openings 2 c of the flap, with which they form a closed unit.
FIG. 6 b . Alternatively, a telescoping rod 13 b is provided between the nut block 13 h and the lower flap 2 . Instead of unlatching, the rod is pushed together and thus be recessed in the lower flap 2 . An spring 13 b embedded in the rod 13 J extends it to its respective length.
FIGS. 6 c and 6 d . Alternatively, a multi-stage hydraulic cylinder 13 c is mounted as a rod, which is placed between the flap 2 and a spot in the fixed side wall 8 . It can not be recessed in the flap 2 , but can be covered. A threaded rod is obsolete.
FIGS. 7 a and 7 b show an example of a closed or open locking mechanism between the lower and upper side flaps 2 and 3 , in the closed or slightly open position. The surrounding closing edges 13 e are trapezoidal and designed as a tongue and groove. By means of a locking bolt 13 d , the closing edges are secured one against the other.
A flap 2 a , 2 b for driving on and off is held in a sealing position by springs. When closing, the flap for driving on and off 2 a is pushed to a vertical position by the upper flap 3 and flushes with the upper flap 3 .
If the lower flap 2 is open, the flap for driving on and off 2 a is pushed against the ramp by means of springs 2 b , as shown in FIG. 9 .
FIG. 8 shows the upper flap 3 with an extensible display panel 16 , in the extended state. A display panel 16 is movable on a holder 16 b and is drawn in with it into an opening 16 a . When the flap 3 is open, the display panel 16 is extended with and by means of the holder 16 b at the front edge of the flap. Since the display panel 16 is mounted on the holder 16 b with hinges, it folds down by its own weight. If the display board 16 is drawn in by the holder 16 b , it folds up.
FIG. 9 shows a top view of a section of the train with an open center, and the roof and the upper flaps 3 removed.
The drawing shows the base plate (body) 4 , side walls 8 fixed to it, lower flaps 2 and the alignment unit 5 , 5 a , with its markings limiting the driveway 6 a and its series of pressure sensors 6 b . Through the middle part of the alignment unit 5 , a toothed ring 5 b and a motor 5 c can be seen.
The wheel case 17 and the springs 17 c are not shown, only the chassis is exposed and visible from above. Movable bearing blocks 17 b with the axle 17 a and the wheels, are shown and an axis drive motor 17 d is mounted on it. Also, a coupling 18 and a coupling mandrel 18 a are shown.
FIG. 9 a shows a top view of a short train section. The alignment unit and a fixed base plate are omitted, only a body 4 a with carrier tracks 4 b is shown. Both are preferably in one plane and are firmly connected. The mobile bearing blocks 7 b with the axle and the wheels 17 a , the coupling 18 and the coupling mandrel 18 a , and on both sides are lower flaps 2 , each with ramp for driving on and off 2 a and the fixed side walls 8 at all side ends are also shown.
FIG. 9 b shows a cross section of the lower flaps 2 , flaps for driving on a and off 2 a , carrier tracks 4 b and the alignment unit 5 , 5 a of an opened train section. Rollers 5 f are attached underneath the alignment unit 5 , 5 a , which run on the carrier tracks 4 b . The lower flaps 2 rest on the ramps 9 . The alignment unit 5 , 5 a is surrounded flush by a ring 5 d , which is interrupted at the folding edges. At the edge of the alignment unit 5 a surrounding cuff 5 e is mounted, which extends across surrounding ring 5 d . Additionally, hinges 7 and the gear ring 5 b are shown.
FIG. 10 shows an example of a cross section of a wheel case 17 . The wheel case 17 is stable and supports the spring load. The axle 17 a is supported by two vertically movable bearing blocks with axle bearings 17 b . The bearing blocks 17 b are each attached by a hinge to the body 4 a . For axle suspension, springs 17 c and/or a shock absorber are mounted between the bearing blocks 17 b and the wheel case 17 . A mounted coupling 18 with a coupling mandrel 18 a are also shown. Advantageously, the chassis is supported on the wheel case 17 with at least one double acting hydraulic adjuster 17 e . This can either be controlled as an active vibration damper, or, when the wagon is stationary, can be used as a height adjustment means, which in conjunction with a ramp sensor 17 f , FIG. 9 b , adjusts the base plate 4 at the level of the top edge of the ramp 9 and which maintains this level also in the case of a changing load due to the driving on and off of the vehicle 11 . This way, the fold-out side panels are fully brought to rest on the ramp 9 and their hinge area in particular is protected from high loads.
The hydraulic actuator 17 e is advantageously driven at its two ports with a 2-channel 2-way valve with intermediate locking position. The control device of the flap comprises a running/stationary signal and level signals from the ramp sensor 17 f and from a position sensor 17 a of the axle in the wheel case 17 , with these sensors in effect alternatively and evaluated by appropriate programs. Preferably, hydraulic actuators 17 e and associated ramp sensors 17 f are arranged respectively on both sides, so that a transverse inclination is prevented.
FIG. 11 shows a cross section through a double-deck train 1 . It is located between ramps 9 . All flaps 2 , 3 , 2 ′, 3 ′ are open. Columns 9 b are placed where there are no flaps, to support of the upper ramp 9 a . The upper vehicle 11 is driving onto the train, the lower vehicle 11 ′ has already been turned. The fixed side walls 8 , the wheel case 17 , the wheels with the axle 17 a and an extended display panel 16 are also shown. The upper floor has a middle plate 4 ′, which is equipped with an alignment unit 5 . The upper and lower flaps 2 ′, 3 ′ on the upper deck are similar to those on the lower deck.
The novel transportation device has the following advantageous features:
that by the arrangement of both mobile and stationary parts of the flaps and the floor flatness is maintained during the entire loading process, and also no breaks in the form of gaps or holes within the entire area of the transportation unit with its flaps open;
that with double or multi-level ramps simultaneous multi-level loading is possible; that each loading unit can be loaded independently, without the other units being affected in any way;
that parts of a rotational disk of the alignment unit are linked by means of hinges or other flexible connections, so that, in a defined position of the disc, in which all axes are in alignment, these parts can be moved like the flaps of a transportation unit;
that all pieces of the alignment unit are automatically fixed or loosened with the transportation unit by closing and opening the side flaps;
that the parts of an alignment unit replace parts of the floor and the side flaps of a transportation unit;
that the alignment unit consists of one piece, and possesses the necessary flexibility in the areas that have to be bent;
that the function of the flaps transportation unit have the function of bridging the gap between the transportation unit and the ramp, and support the carrier rail for the alignment unit;
that a circular disk of the alignment unit, which can be rotated centrally, and on two opposite sides has sections that can be folded by means of hinges or due to the flexibility of the material, has several functions (rotate, open-close, fix, replace parts) that are carried out by means of appropriate actuators;
that carrier tracks are placed in flaps of a transportation unit;
that an alignment unit is surrounded flush by a ring, which is interrupted at the folding edges, and that at the edge of the of the alignment unit a surrounding cuff is mounted, which extends across surrounding ring;
that threaded rods are mounted in the side walls of a transportation unit, which move nut blocks that are guided in rails up and down, and that the nut blocks are connected to the flaps by a rod, by which they are opened and closed;
that the ends of the rods that connect the nut blocks are T-shaped, unlatch when the flap is opened and are sunk in a recess/opening in the lower flap;
that a rod, which connects the nut blocks with the flaps is collapsible, is held in an extended position by a spring and is recessed in an opening in the lower flap;
that the lower flaps have recesses/openings for receiving rods;
that hooks in the flaps are specially shaped and thus a rod unlatches when the flap is open;
that multi-stage hydraulic cylinders attached in the side walls open and close the flaps;
that the closing areas between the flaps and between flaps and walls are trapezoidal and engage;
that, when the flaps are closed, bolts lock the flaps with each other or with the walls;
that a flap for driving on and off that is hinged on the lower flap and is forced to a defined angular position by means of springs;
that a display panel is hinged and movable on a rail/holder and that together they are placed inside the upper flap of a transportation unit; when the flap is open, the display panel is extended by means of the rods at the front edge of the flap, and (by its own weight) it swings down to a position in which it can be seen well by the driver of the vehicle; that traffic lights/display panels are attached in the fixed walls next to the flaps, at the outside and inside of the train;
that markings and pressure sensors are placed on an alignment unit;
that the axle with wheels, drive and brake (partly) is surrounded by a wheel case, which projects above the level of the base plate (the floor) of a transportation unit;
that a wheel case receives the spring load of a transportation unit via springs/shock absorbers;
that the axle is supported in blocks, which are hinged at the body/fixed base and that springs/shock absorbers located between the axle blocks and the wheel case provide the suspension for the transportation unit;
that hydraulic height adjusters, mounted between the axle blocks and the wheel case, stabilize the train during the loading process and adjust its height using ramp sensors.
The transportation unit can advantageously be designed as an articulated train, wherein especially for double-deck trains, it is advantageous that a structural wall is supported on the wheel case.
LIST OF REFERENCE SYMBOLS
1 train/transportation unit
2 lower flap, 2 a flap for driving on a and off, 2 b spring, 2 c recess/opening,
2 ′ lower double-deck flap, 2 a ′ upper flap for driving on and off
3 upper flap, 3 windows, 3 ′ upper double-deck flap
4 fixed base plate, 4 a body, 4 b carrier track, 4 ′ middle plate with alignment unit 5 ′
5 alignment unit, 5 a wing right-left, 5 b toothed ring (live ring), 5 c motor,
5 d surrounding ring, 5 e cuff, 5 f rollers, 5 ′ alignment unit in 4 ′
6 driveway limit, 6 a driveway limit markings, 6 b pressure sensors
7 hinges
8 fixed side walls
9 ramp, 9 a columns, 9 ′ upper ramp
10 rails
11 vehicle to be transported, bottom vehicle, 11 ′ top vehicle
12 oblong alignment unit
13 closing-opening mechanism of the flaps, 13 rod with T-shape, 13 b telescopic rod
13 c rod as a multi-stage hydraulic cylinder, 13 d bolts for locking, 13 e surrounding closing edge, trapezoidal, 13 f specially shaped hook, 13 g threaded rod, 13 h nut block, 13 i guiding rail, 13 j spring in rod
14 closing/opening mechanism of the upper flaps
15 passage
16 display panel, 16 a opening in upper flap, 16 b holder
17 wheel case, 17 a wheels with axle, 17 b bearing block with axle bearings,
17 c springs/shock absorbers, 17 d driving motor/axle motor and brake, 17 e hydraulic height adjuster, 17 f ramp sensor
18 coupling, 18 a coupling mandrel
FL vehicle length
FB vehicle width
TB width of the transportation unit | A transportation unit, such as a wagon and/or train, includes at least one plate-shaped alignment unit, which can rotate about a vertical axis, for picking up a vehicle from a ramp and aligning it. The length of the vehicle exceeds a useful width of the transportation unit, but the width of the vehicle does not project beyond the transportation unit. The alignment unit is mounted on the floor of the transportation unit so as to rotate on a carrier track. The transportation unit carries respective flaps which can pivot onto the ramp or ramps and onto which the carrier tracks extend and as a result also support the alignment unit in a rotated, partially projecting-out state at that location. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for screening an obesity prevention or treatment agent, and a method for preparing an obesity prevention or treatment agent.
[0003] 2. Description of the Related Art
[0004] Obesity is a medical condition in which excess body fat has accumulated to the extent that it may have an adverse effect on health. This does not refer to a condition of excessive bodyweight, but rather a condition where fat has excessively accumulated in the body due to a metabolic disorder. That is, calorie intake exceeds energy required for body activity and growth so that calories are excessively accumulated in the form of triglycerides in adipose tissues, thus causing obesity. Even in itself, obesity not only prompts disfigurement, discomfort and disability, but also causes various diseases, including cardiovascular diseases, such as hyperlipidemia, hypercholesterolemia, hypertension, arteriosclerosis, myocardial infarction and the like, as well as renal disease, type II insulin-independent diabetes, and pulmonary disease, which may lead to death. In advanced countries, 30% of the adult population is obese, and particularly, obese men in a young age group (25-34 years old) were measured to have about a 12-times higher mortality rate than normal men, predominantly due to cardiovascular diseases.
[0005] In order to treat obesity, studies are currently being performed on diet therapy, exercise therapy, behavior modification therapy, surgical therapy, drug therapy and the like. Of them, drugs for treating obesity have been particularly extensively developed, as exemplified by fat accumulation inhibitors (appetite inhibitors, and agents for suppressing food absorption or fatty acid production) and fat utilization stimulants (thermogenic or lipolytic agents). Fluoxetine, orlistat, and sibutramine have recently been widely used in the clinical field. However, fluoxetine (sold under the trade name “Prozac”), used as an antidepressant with the function of selectively inhibiting serotonin reuptake, is known to have only a temporary effect on the reduction of bodyweight, but with the concomitant occurrence of side effects, such as enervation, perspiration and lethargy. Orlistat (sold under the trade name “Xenical”) inhibits the activity of lipase in the small intestines to reduce fat absorption by about 30%, but causes steatorrhea and requires the supplement of fat-soluble vitamins with long-term administration. Sibutramine (sold under the trade name “Reductil”) shows the double action of inhibiting the reuptake of serotonin and norepinephrine. An increase in serotonin activates the sympathetic system to incite an exothermic reaction in brown fat tissue, but causes side effects, such as blood pressure increase, mouth drying, constipation and insomnia. Therefore, there is a pressing need for the development of an anti-obesity agent that is safe and effective.
[0006] Recent studies have demonstrated that the expression of neuropeptide Y (NPY), which mediates the action of reptin in the hypothalamus, is upregulated in reptin/reptin receptor-deficient mice, and that the deletion of the neuropeptide Y gene is less likely to make reptin-deficient mice obese. Neuropeptide Y is a 36-amino acid neuropeptide secreted from the pancreas which belongs to the neuroendocrine peptide family, and is abundantly found in the mammalian central and peripheral nervous systems, particularly, in the hypothalamus and the cortex.
[0007] Meanwhile, GABA (Gamma Amino Butyric Acid), a kind of non-protein amino acids widely found in nature, is the chief inhibitory neurotransmitter in the mammalian brain and spinal cords. It plays a role in various physiological mechanisms, including the activation of the metabolism of cerebral cells by increasing cerebral blood flow and oxygen supply. GABA is found at high concentrations in the cerebral cortex and the cerebellar gray and white matter, and distributed over almost all areas of the brain, such as the hippocampus, thalamus, striatum, olfactory bulb, myelencephalon, etc. When released to synapses, GABA binds to membrane proteins of postsynaptic neurons via GABA receptors. There are two classes of GABA receptors: GABA A and GABA B . GABA A receptors are ligand-gated ion channels which are opened upon activation to allow the selective influx of Cl − through their pores, resulting in hyperpolarization of the neuron whereas GABA B receptors are G protein-coupled receptors which can stimulate the opening of K + channels, showing indirect inhibitory activity. However, thus far there has been no definite correlation suggested between GABA B receptors and obesity nor between GABA B receptors and neuropeptide Y, nor for the mechanisms of GABA B receptors and neuropeptide Y for the prevention and treatment of obesity.
[0008] In the background of this pressing need for safe anti-obesity agents that do not provoke side effects, intensive and thorough research into the screening of such anti-obesity agents resulted in the finding that candidate substances for the effective and safe therapy of obesity can be screened by monitoring changes in the expression level of GABA B receptors and neuropeptide Y, which led to the present invention.
SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to provide a method for screening an obesity prevention or treatment agent, comprising: (a) measuring expression level of GABA B receptor and neuropeptide Y in a subject; (b) administering a candidate substance to the subject, followed by measuring expression level of GABA B receptor and neuropeptide Y in the subject; and (c) determining the candidate substance as an obesity prevention or treatment agent when the expression level of GABA B receptor in step (b) is found to have increased compared to step (a) and the expression level of neuropeptide Y in step (b) is found to have decreased compared to step (a).
[0010] It is another object of the present invention to provide a method for preparing an obesity prevention or treatment agent, comprising (a) administering a candidate substance to a subject, followed by examining upregulated expression of GABA B receptor and downregulated expression of neuropeptide Y in the subject; and (b) adding the candidate substance to a composition when the candidate substance upregulates the expression of GABA B receptor and downregulates the expression of neuropeptide.
Effect of the Invention
[0011] Being able to easily detect a substance that has a preventive and therapeutic effect on obesity, the present invention has a wide spectrum of applications in the research and medicine fields for the prevention or treatment of obesity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows graphs of body weight changes (A) and daily food uptake (B) in animals with or without administration of anthocyanin.
[0013] FIG. 2 shows fluorescent images comparing the sizes of epididymal white adipose tissues excised from animals without administration of anthocyanin (A) or with administration of anthocyanin at a dose of 6 mg (B) and 24 mg (C).
[0014] FIG. 3 shows an image of GABA B receptor blots illustrating expression level in the hypothalamus of animals with or without administration of anthocyanin, as measured by Western blotting (A), and a graph analyzing densities of the protein according to the group (B).
[0015] FIG. 4 shows an image of neuropeptide Y blots illustrating expression level in the hypothalamus of animals with or without administration of anthocyanin, as measured by Western blotting (A), and a graph analyzing densities of the protein according to the group (B).
[0016] FIG. 5 shows images of PKA-α (A) and p-CREB (B) blots illustrating expression levels in the hypothalamus of animals with or without administration of anthocyanin, as measured by Western blotting, and graphs analyzing densities of the proteins according to the group.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] In accordance with an aspect thereof, the present invention provides a method for screening an obesity preventive or therapeutic agent, comprising administering a candidate substance to a subject and measuring expression levels of GABA B receptor and neuropeptide Y. In detail, the screening method of the present invention comprises: (a) measuring expression level of GABA B receptor and neuropeptide Y in a subject; (b) administering a candidate substance to the subject, followed by measuring expression level of GABA B receptor and neuropeptide Y in the subject; and (c) determining the candidate substance as an obesity prevention or treatment agent when the expression level of GABA B receptor in step (b) is found to have increased compared to step (a) and the expression level of neuropeptide Y in step (b) is found to have decreased compared to step (a).
[0018] In accordance with another aspect thereof, the present invention provides a method for preparing an obesity prevention or treatment agent, comprising (a) administering a candidate substance to a subject, followed by examining upregulated expression of GABA B receptor and downregulated expression of neuropeptide Y in the subject; and (b) adding the candidate substance to a composition when the candidate substance upregulates the expression of GABA B receptor and downregulates the expression of neuropeptide.
[0019] As used herein, the term “subject” refers to any mammal that expresses GABA B receptor and neutopeptide Y, including, but not limited to, dogs, cows, horses, rabbits, mice, rats, chickens, and humans. Preferably, rats may be employed to measure expression levels of GABA B receptor and neuropeptide Y.
[0020] As used herein, “GABA B receptor” is a receptor that responds to the neurotransmitter GABA (Gamma Amino Butyric Acid), and is composed of two subunits GABA B1 and GABA B2 . The GABA B receptor is a member of the superfamily of G protein-coupled receptors, also known as seven-transmembrane domain receptors. When activated, the GABA B receptor stimulates the opening of K + channels to exhibit indirect inhibition, modulating the secretion of inhibitory neurotransmitters. Correlation between GABA B receptor and obesity has not yet been definitely described until now. The present inventors first found the upregulated expression of GABA B receptor by an anti-obesity substance (anthocyanin), which has been developed to a screening method by which a candidate substance is determined as an obesity prevention and treatment agent if the expression of GABA B receptor is upregulated by treatment with the candidate substance.
[0021] The term “neuropeptide Y (NPY),” as used herein, means a 36-amino acid neuropeptide belonging to the neuroendocrine peptide family which is abundantly found in the mammalian central and peripheral nervous systems, particularly, in the hypothalamus and the cortex. However, thus far there have been no definite suggestions for a correlation between GABA B receptor and obesity nor between GABA B receptor and neuropeptide Y, nor for mechanisms of GABA B receptor and neuropeptide Y on the prevention and treatment of obesity. Based on their first discovery that an anti-obesity substance (anthocyanin) upregulates the expression of GABA B receptor and down-regulates the expression of neuropeptide Y, the present inventors designed a screening method by which a candidate substance is determined as an obesity prevention and treatment agent if the candidate substance acts to upregulate the expression of GABA B receptor and downregulate downregulate the expression of neuropeptide Y. It was first found by the present inventors that an anti-obesity substance decreases the expression level of neuropeptide Y and increases the expression level of GABA B receptor.
[0022] As used herein, the term “candidate substance” means any substance that is expected to prevent or treat obesity, and particularly refers to a target to be tested for ability to prevent and treat obesity through the mechanism of modulating expression of GABA B receptor and neuropeptide Y. Examples of the candidate substance include, but are not limited to, proteins, oligopeptides, small organic molecules, polysaccharides, polynucleotides and various compounds. They may be synthetic as well as natural.
[0023] As used herein, the term “obesity prevention agent” is intended to refer to any substance that brings about the suppression or delay of the onset of certain obesity-induced diseases thanks to the administration thereof. The term “obesity treatment agent” is intended to refer to any substance that brings about improvements in symptoms of certain obesity-induced diseases or the beneficial alteration of the diseases thanks to the administration thereof.
[0024] The composition to which the candidate substance is added in the preparation method of an obesity prevention or treatment agent may further comprise a pharmaceutically acceptable vehicle. The composition comprising a pharmaceutically acceptable vehicle may be in various oral or non-oral dosage forms. In this regard, the composition of the present invention may be formulated in combination with a diluent or excipient such as a filler, a thickener, a binder, a wetting agent, a disintegrant, a surfactant, etc. Solid preparations intended for oral administration may be in the form of tablets, pills, powders, granules, capsules, and the like. In regards to these solid agents, the active ingredient of the present invention is formulated in combination with at least one excipient such as starch, calcium carbonate, sucrose, lactose, or gelatin. In addition to a simple excipient, a lubricant such as magnesium stearate, talc, etc. may be used. Among liquid preparations intended for oral administration are suspensions, internal use solutions, emulsion, syrups, and the like. Plus a simple diluent such as water or liquid paraffin, various excipients, such as wetting agents, sweeteners, aromatics, preservatives, and the like may be contained in the liquid preparations. Also, the composition may be in a parenteral dosage form such as sterile aqueous solutions, non-aqueous solvents, suspensions, emulsions, lyophilizates, suppositories, and the like. Injectable propylene glycol, polyethylene glycol, vegetable oils such as olive oil, and esters such as ethyl oleate may be suitable for the non-aqueous solvents and suspensions. The basic materials of suppositories include Witepsol, macrogol, Tween 61, cacao butter, laurin butter, and glycerogelatin. The composition may be in a dosage form selected from the group consisting of a tablet, a pill, a powder, a granule, a capsule, a suspension, an internal use solution, an emulsion, a syrup, an sterile aqueous solution, a non-aqueous solvent, a suspension, a lyophilizate, and a suppository.
[0025] The term “obesity,” as used herein, means a condition where fat is excessively accumulated in the body due to a metabolic disorder. Obesity is known to prompt disfigurement, discomfort and disability in itself, but also causes various diseases, including cardiovascular diseases, such as hyperlipidemia, hypercholesterolemia, hypertension, arteriosclerosis, myocardial infarction and the like, renal disease, type II insulin-independent diabetes, and pulmonary disease.
[0026] The term “screening,” as used herein, means finding out a certain property, including susceptibility to or activity on a certain compound, such as an antibiotic, an enzyme, etc.
[0027] In the present invention, after administration with a candidate substance which is expected to upregulate the expression of GABA B receptor and to downregulate the expression of neuropeptide Y, rats which express GABA B receptor and neuropeptide Y are monitored for expression patterns of GABA B receptor and neuropeptide Y to examine whether the candidate substance can be used as an obesity treatment agent by modulating the expression of the proteins. In detail, when a candidate substance is observed to upregulate the expression of GABA B receptor while down-regulating the expression of neuropeptide Y in the subject administered therewith, the candidate can be determined to be an obesity prevention and treatment agent. For the screening of obesity prevention or treatment agents, preferably, reference may be made to expression levels of GABA B receptor and neuropeptide Y in the hypothalamus.
[0028] In one embodiment of the present invention, anthocyanin, known to exert an anti-obesity effect on adult rats, was demonstrated to induce the upregulated expression of GABA B receptor ( FIG. 3 ) and the downregulated expression of neuropeptide Y ( FIG. 4 ) in rats, indicating that a modulation in the expression level of GABA B receptor and neuropeptides Y can be used as an index for screening an obesity prevention and treatment agent.
[0029] In one embodiment, the screening method according to the present invention further comprising measuring expression level of PKA-α or p-CREB in the steps (a) and (b), and determining the candidate substance as an obesity prevention or treatment agent when the expression level of PKA-α in step (b) is found to have decreased compared to step (a) or the expression level of p-CREB in step (b) is found to have increased compared to step (a).
[0030] In the screening method of the present invention, the candidate substance may be confirmed as usable as an obesity prevention and treatment agent or not by monitoring a modulation in the expression levels of PKA-α and p-CREB, the activities of both of which are controlled with regard to the neurotransmission of GABA B receptor. In detail, if a candidate substance that acts to upregulate the expression of GABA B receptor and downregulate the expression of neuropeptide Y in a subject is further observed to decrease the expression of PKA-α and increase the expression of p-CREB, simultaneously, in the subject, the candidate substance is confirmatively determined as an obesity prevention and treatment agent.
[0031] As used herein, the term “PKA-α (protein kinase A-α)” refers to a protein acting as a second messenger in GABA receptors, which is reported to induce various intracellular changes including cAMP, activate protein kinases through a change in the phosphorylation thereof, and to control the expression levels of downstream genes.
[0032] As used herein, the term “CREB (cyclic AMP response element binding protein)” is a cellular transcription factor which is phosphorylated by activated PKA to increase the description of related genes. Particularly, CREB is known as an essential transcription factor which continues to be expressed in preadipocytes before and during differentiation to adipocytes and binds to promoters of adipocyte-specific genes to regulate the description of the genes.
[0033] In one embodiment, anthocyanin, known to exert an anti-obesity effect on rats, was demonstrated to induce the downregulated expression of PKA-α receptor ( FIG. 5A ) and the upregulated expression of p-CREB ( FIG. 5B ) in rats, indicating that a modulation in the expression levels of PKA-α and p-CREB can be used as an additional index for screening an obesity prevention and treatment agent.
[0034] In the screening method of the present invention, the measurement of expression modulations of GABA B receptor, neuropeptide Y, PKA-α, and p-CREB may be achieved using any technique that is typically used in the art. The expression of GABA B receptor, neuropeptide Y, PKA-α, and p-CREB may be quantitatively analyzed at the level of mRNAs or proteins encoded by the mRNAs. For the quantitation of mRNAs, for example, complementary primer or probe sequences may be used while protein levels may be determined using antibody binding to proteins or their fragments. Preferably, the expression of GABA B receptor, neuropeptide Y, PKA-α or p-CREB may be measured at a protein level using Western blot.
[0035] As used herein, the term “determination of mRNA expression level” refers to a process of measuring the mRNA level of GABA B receptor, neuropeptide Y, PKA-α, or p-CREB in a subject administered with a candidate substance to screen an obesity prevention and treatment agent. To this end, the technique of measuring mRNA levels may include, but is not limited to, reverse transcription polymerase chain reaction (RT-PCR), competitive RT-PCR, real-time RT-PCR, RPA (RNase protection assay), Northern blotting, and DNA chip.
[0036] The “determination of protein expression level” in the present invention is a process of qualitatively and quantitatively analyzing proteins expressed from the mRNAs of GABA B receptor, neuropeptide Y, PKA-α or p-CREB in a subject administered with a candidate substance to screen an obesity prevention and treatment agent, preferably using antibodies specifically binding to the proteins of the genes. In this regard, the measurement of the protein levels may be achieved by an immunoassay using an antibody specific for each of GABA B receptor, neuropeptide Y, PKA-α and p-CREB, examples of which include, but are not limited to, Western blotting, ELISA (enzyme linked immunosorbent assay), radioimmunoassay (RIA), radioimmunodiffusion, ouchterlony immunodiffusion, rocket immunoelectrophoresis, histoimmunochemical staining, immunoprecipitation assay, complement fixation assay, FACS, and protein chip. Further, analysis using an antibody may recruit a detectable marker-labeled second antibody specific for a target protein while a detectable marker-labeled third antibody having affinity for the second antibody may be optionally used. The detectable marker labeled to the second or the third antibody may be an enzyme which can develop a color while being cultured in the presence of a suitable chromogenic substrate. The detectable maker can include compositions that are detectable by spectroscopicc, enzymatic, photochemical, biochemical, bioelectronic, immunochemical, electric, optical, or chemical means, as exemplified by, but not limited to, fluorescent markers and dyes, magnetic labels, linked enzymes, mass spectrometry tags, spin labels, electron transfer donors and acceptors, and the like.
[0037] A better understanding of the present invention may be obtained through the following examples which are set forth to illustrate, but are not to be construed as limiting the present invention.
Reference Example 1
Preparation of Tissues and Samples
[0038] For hematoxylin-eosin staining, an epididymal white adipose tissue (WAT) was fixed at 4° C. for 72 hrs in ice-chilled 1× PBS containing 4% para-formaldehyde, and immersed at 4° C. for 72 hrs in 20% sucrose sucrose phosphate buffer for cryoprotection. The fixed tissue was frozen with O.C.T compound (A. O. USA), and 10 μm coronal sections were made in coronal planes (Leica cryostat CM 3050, Germany). The sections were mounted on a probe-on, positively charged slide at room temperature and stored at −70° C. until use.
Example 1
Assay for Preventive and Therapeutic Effect of Anthocyanin on Obesity
[0039] For use in assay for the preventive and therapeutic effect of anthocyanin on obesity, male Sprague-Dawley rats, 60 days old (the Experimental Animal Breeding Center of the Gyeongsang National University, Jinju, Korea)) were divided groups of four which were then orally administered with anthocyanin at a dose of 6 mg and 24 mg, respectively, or not administered with anthocyanin for a control. They were maintained for 40 days in a temperature-controlled condition with lighting 06:00-20:00. While being maintained, the rats in each group were monitored for weight change and daily food uptake, and the results are shown in FIG. 1 . FIG. 1 shows graphs of weight changes (A) and daily food uptake (B) in animals with or without administration of anthocyanin.
[0040] As can be seen in FIG. 1 , weight was increased by 69 g from 32.33 g to 101.33 g in the group administered with 6 mg of anthocyanin and by 69.67 g from 28.33 g to 98 g in the group administered with 24 mg of anthocyanin. The anthocyanin-administered rats were significantly less apt to gain weight, compared to the non-administered control which was measured to increase in weight by 79.33 g from 37 g to 116.33 g ( FIG. 1A ). In addition, daily food uptake was significantly decreased in the group administered with 24 mg of anthocyanin (16.43 g), compared to the control (20.03 g) ( FIG. 1B ).
Example 2
Measurement of Epididymal White Adipose Tissue
[0041] The animals bred as in Example 1 were collectively sacrificed at 10:00 AM 40 days after the oral administration, and epididymal white adipose tissue (WAT) was excised from each sacrificed animal and used for comparison of obesity. The epididymal WAT was fixed at 4° C. for 72 hrs in ice-chilled 1× PBS containing 4% para-formaldehyde, and immersed at 4° C. for 72 hrs in a 20% sucrose phosphate buffer for cryoprotection. The fixed tissue was frozen with O.C.T compound (A. O. USA), and 10 μm coronal sections were made in coronal planes (Leica cryostat CM 3050, Germany). The sections were mounted on probe-on, positively charged slides and thawed at room temperature for 3 hrs. The thawed slides were washed twice for 15 min in PBS, stained for 3 min with hematoxylin-eosin, and then washed again for 1 min with distilled water, followed by treatment with ethanol (70 to 100%) and 100% xylene for 3 min each. Cover slips were mounted on the slides which were observed under a fluorescence microscope at 400× magnification. The results are given in FIG. 2 . FIG. 2 shows fluorescent images comparing sizes of epididymal white adipose tissues excised from animals without administration of anthocyanin (A) or with anthocyanin at a dose of 6 mg (B) and 24 mg (C).
[0042] As can be seen in FIG. 2 , the number of adipocytes per unit area was larger in the animals administered with anthocyanin at a dose of 6 mg (22.47 cells/250 mm 2 ) (B) and 24 mg (22.8 cells/250 mm 2 ) (C) than in the control (18.75 cells/250 mm 2 ) (A), indicating adipocytes were reduced in size by treatment with anthocyanin. These data suggested that anthocyanin can be used as an obesity prevention and treatment agent.
Example 3
Effect of Obesity Prevention and Treatment Agent on Expression of GABA B Receptor
[0043] To examine the effect of an obesity prevention and treatment agent on the expression of GABA B receptor, the animals maintained as in Example 1 were collectively sacrificed at 10:00 AM 40 days after the oral administration, and the hypothalamus was excised from each of them. The hypothalamic sample was homogenized in 0.2 M PBS containing a protease inhibitor cocktail. Protein levels were measured using a Bio-Rad protein analysis solution, and after two rounds of ultracentrifugation at 4° C. and 12,000 rpm for 20 min, the supernatants containing proteins were separated. The supernatants were loaded in an aliquot of 30 μl per lane to 10-18% gel and subjected to SDS-PAGE, followed by transfer to a polyvinylidene difluoride (PVDF) membrane. This membrane was blocked with 5% (v/v) skim milk to reduce non-specific binding, and incubated with a primary goat anti-GABA B R1 antibody (1:200; Santa Cruz Biotechnology, Santa Cruz, Calif., USA) and an anti-beta-actin antibody for quantitative comparison, followed by immune reaction with a secondary HRP (horseradish peroxidase)-conjugated anti-goat and anti-rabbit IgG (1:1000; Santa Cruz Biotechnology, Santa Cruz, Calif., USA). Protein levels were determined by chemiluminescence using ECL-detecting reagent (Amersham Pharmacia Biotech, Western blotting detection reagents). Western blots on the X-ray film were analyzed by densitometry using computer-based Sigma Gel (SPSS Inc. Chicago, USA), and the results are shown in FIG. 3 . FIG. 3 shows an image of GABA B receptor blots illustrating expression levels in the hypothalamus of animals with or without administration of anthocyanin, as measured by Western blotting (A), and a graph analyzing densities of the protein according to the group (B).
[0044] As can be seen in FIG. 3 , the animals which were prevented from becoming obese by being administered anthocyanin were observed to have an increased expression level of GABA B receptor in the hypothalamus, suggesting that the upregulated expression of GABA B receptor in the hypothalamus can be used as an index for screening an obesity prevention and treatment agent.
Example 4
Effect of Obesity Prevention and Treatment Agent on Expression of Neuropeptide Y
[0045] To examine the effect of an obesity prevention and treatment agent on the expression of neuropeptide Y, expression level of neuropeptide Y was measured in a manner similar to that of Example 3, except for using a primary goat anti-NPY antibody (1:200; Santa Cruz Biotechnology, Santa Cruz, Calif., USA), and the results are given in FIG. 4 . FIG. 4 shows an image of neuropeptide Y blots illustrating expression level in the hypothalamus of animals administered anthocyanin and those not, as measured by Western blotting (A), and a graph analyzing densities of the protein according to the group (B).
[0046] As can be seen in FIG. 4 , the animals which were prevented from being obese by administration with 24 mg of anthocyanin were observed to have a decreased expression level of neuropeptide Y in the hypothalamus, suggesting that the downregulated expression of neuropeptide Y in the hypothalamus can be used as an index for screening an obesity prevention and treatment agent.
Example 5
Effect of Obesity Prevention and Treatment Agent on Expression of Proteins Downstream of GABA B Receptor
[0047] An examination was made of the effect of an upregulated expression of GABA B receptor on the downstream signaling mechanism in the hypothalamus of an obesity-suppressed animal. In this regard, PKA-α and p-CREB, both known to modulate in expression depending on GABA B receptor, were analyzed for expression level in the same manner as in Example 3, except for using a primary goat anti-PKAα antibody (1:200; Santa Cruz Biotechnology, Santa Cruz, Calif., USA) and a primary goat anti-p-CREB antibody (1:200; Santa Cruz Biotechnology, Santa Cruz, Calif., USA), and the results are given in FIG. 5 . FIG. 5 shows images of PKA-α (A) and p-CREB (B) blots illustrating expression level in the hypothalamus of animals administered anthocyanin and those not, as measured by Western blotting, and graphs analyzing densities of the proteins according to the group.
[0048] As can be seen in FIG. 5 , the animal group which was prevented from being obese by administration with 24 mg of anthocyanin was observed to show a decrease in the expression level of PKA-α in the hypothalamus ( FIG. 5A ), but to show an increase in the expression level of p-CREB ( FIG. 5B ). Taken together, these results demonstrate that modulated expression levels of PKA-α and p-CREB in the hypothalamus of a subject can be used as an additional index for screening an obesity prevention and treatment agent. | The present invention relates to a method for screening and preparing an obesity prevention or treatment agent, and a method for preparing an obesity prevention or treatment agent. Being able to easily detect a substance that has a preventive and therapeutic effect on obesity, the present invention has a wide spectrum of applications in the research and medicine field in the prevention or treatment of obesity. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
Automotive Brake Dust Recovery Unit.
2. Description of the Prior Art
In the servicing of the brakes of an automotive vehicle the brake drum, backing plate and shoe assemblies are invariably found to have dust and foreign particled material associated therewith, and at least a portion of the particled material being asbestos or an asbestos containing material. Asbestos has been found to be highly detrimental when breathed, and in many states it is mandatory that asbestos dust not be allowed to escape to the ambient atmosphere.
A major object of the present invention is to provide an apparatus that may be moved to a position adjacent a brake assembly after the wheel associated with the assembly has been removed therefrom, with the apparatus then being removably secured to the brake assembly to subject the latter to a current of air to separate dust and particled foreign material therefrom with the current of air with entrained particled material being directed to a confined space within a tank where it is subjected to a washing operation, and the washed air then being subjected to a filtering operation prior to being discharged to the ambient atmosphere.
Another object of the invention is to supply a brake dust recovery unit that not only separates dust and particled material from a brake drum assembly by subjecting the latter to a current of air, but in addition also separates dust and particled material from the drum by subjecting the interior of the drum and the brake shoe assemblies therein to a rotating blast of air.
Yet another object of the invention is to supply a brake dust recovery unit that removes dust and particled foreign material from a brake drum assembly, and permits maintenance work to be performed on the brake drum assembly without danger of the person carrying out this maintenance work breathing air contaminated with dust and particled foreign material that may in whole or in part be asbestos fibers or fibers containing a substantial quantity of asbestos.
SUMMARY OF THE INVENTION
The invention includes a movable base that supports a tank, a motor driven vacuum pump, and a motor driven water pump. A first flexible hose is connected to the suction side of the vacuum pump, with the free end of the hose having a hood assembly thereon that may be removably attached to an automotive wheel assembly after the wheel has been removed therefrom. When the vacuum pump is operated, an air stream is drawn through the hood through air scoops provided therein to flow over the interior of the brake assembly to remove dust and foreign particled material therefrom, with the air stream having the removed particled material therein being discharged into a confined space defined in the tank.
The tank contains a quantity of water, which water when the motor driven water pump is operating is recirculated to discharge as a spray over a removable screen situated within the confined space through which the air with entrained foreign particles flows, and the air spray removing the major portion of the particled material from the air stream. After the air stream has been subjected to the action of the water spray, the air stream discharges to a filter that is of sufficiently fine mesh as to remove any foreign entrained material from the airstream prior to the air stream being discharged to the ambient atmosphere.
During the removal of dust and foreign particled material from the interior of the brake drum assembly as above-described, the interior of the brake drum and the brake shoe assemblies therein is subjected to a rotating blast of air that separates dust and foreign particled material from the interior of the drum and from the brake shoe assemblies that tend to adhere thereto and would not be removed simply by the action of a stream of air flowing thereover. After dust and foreign particled material has been removed from the brake drum assembly as above-described, the hood is removed therefrom, and the wheel may now be repositioned on the supporting shaft. Due to action of the brake dust recovery unit, maintenance work may be performed on a brake assembly, without danger of the person conducting the maintenance operation breathing air that is contaminated with foreign particled material that may in whole or in part be defined by asbestos or asbestos containing material.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of the brake dust recovery unit;
FIG. 2 is a longitudinal cross-sectional view of the hood portion of the brake dust recovery unit and with the same removably secured to the exterior of a brake drum;
FIG. 3 is an end elevational view of the hood assembly;
FIG. 4 is a vertical cross-sectional view of the tank portion of the brake dust recovery unit; and
FIG. 5 is a schematic wiring diagram of the electric circuit used in the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The automotive brake dust recovery unit A is shown in perspective is FIG. 1. The invention A is used to remove dust and foreign particled material from an automotive wheel support assembly B illustrated in FIG. 2, which assembly includes brake shoes 10 and backing plate 12. A generally cylindrical hood C is provided that has circumferentially spaced air scoops 14 defined on the exterior thereof, and the hood being connected to a first conduit 16 that is in communication with a confined space 18 defined within a tank assembly D as shown in FIG. 4. The tank assembly D is illustrated as supporting a vacuum pump E that has the suction side thereof connected to the confined space 18 by a second conduit 20.
A combined movable screen and wash assembly F is situated within the confined space 18 and serves to remove dust and foreign material from a stream of air that is drawn through the air scoops 14 and has dust and foreign material from the automotive wheel support assembly B entrained therewith. The discharge of the vacuum pump E is connected to a third conduit 22 that extends to a filter assembly G as may be seen in FIG. 1. The filter assembly G serves to remove any entrained dust or particled material that is not removed from the stream of air by the combined screen and wash assembly F in the confined space 18. When the air discharges from the filter assembly G to the ambient atmosphere, all entrained dust or particled material previously associated therewith has been removed either by the screen and wash assembly F or the filter assembly G.
The hood C as may best be seen in FIG. 2 includes a first portion C-1 that is formed from a pliable sheet material, such as plastic or the like, and has a generally cylindrical shape. The first hood portion C-1 has a first end 24 and second end 26. The first end 24 has a resilient band 28 situated therein, which band tends to maintain the first hood portion C-1 in a transverse circular configuration. The band 28 has an internal diameter such that it slidably and snugly engages the external surface of the backing plate 12 as may be seen in FIG. 2.
A ring-shaped seal 30 is situated within the first hood portion C-1 adjacent the first end 24 thereof, with the seal 30 having an internal diameter such that it slidably and sealingly engages the exterior surface of the brake shoe 10. The hood C is preferably manually mounted on the backing plate 12 and held thereon during the recovery of dust and foreign particled material from the backing plate 12, the interior of the shoes 10, and the brake cylinder assemblies (not shown) situated within the brake shoes. The air scoops 14 develop into openings 32 formed in the hood portion C-1 and through which openings air is drawn from the ambient atmosphere as a stream to remove dust and foreign particled material from the interior of the brake shoes. The hood C also includes a second portion C-2 as may be seen in FIG. 2 that is of generally L-shape and formed from a rigid material. The second hood portion C-2 includes a first end portion 34 that has a cylindrical flange 36 that forms a part of the first hood portion C-1 bonded to the interior surface thereof. The second hood portion C-2 develops into a second end portion 38 that is of substantially smaller transverse cross section than the first end portion 34 as may be seen in FIG. 2. The second hood portion C-2 has an eye bolt 40 extending upwardly therefrom, the purpose of which will later be explained. A transverse spider 42 is disposed within the second hood portion C-2 adjacent the first end 34 thereof, with the spider including a hub 44 in which a bearing 46 is supported. The spider 42 has a plate 48 secured thereto on which a first electric motor 50 is mounted as may best be seen in FIG. 3.
The first electric motor 50 includes a drive gear 52. A tubular member 54 is rotatably supported in the bearing 46, and this tubular member including a first straight portion 54a, a second portion 54b that is substantially normal to the first portion, and a third portion 54c that is normal to the free end of the second portion 54b. The first tubular portion 54a has a cylindrical body 56 mounted on the free end portion thereof as shown in FIG. 2, and this body 56 having a driven gear 58 secured thereto, and the driven gear being in toothed engagement with the driving gear 52. A cylindrical rib 60 extends outwardly from the body 56 away from the spider 42, with the rib supporting a bearing 62 that includes inner and outer races. The inner race of the bearing 62 is secured to a first horizontal tube 64 that develops into a second vertically extending tube 66 as illustrated in FIG. 2. The second tube 66 communicates with a normally closed valve 68 that is placed in the open position by use of a handle 70. The valve 68 is supported in a fixed position relative to the hood C by a cylindrical support 72 that extends downwardly from the second hood portion C-2 as shown in FIG. 2. The valve 68 is by a fitting 74 connected to a flexible conduit 76 that extends to a source of pressurized air that will normally be available in establishments in which brake assemblies of automobiles are serviced.
The vacuum pump E as may be seen in FIG. 1 is actuated by a second electric motor 78. The tank assembly D as may be seen in FIGS. 1 and 4 includes a tank 80 that has a bottom 80a, a cylindrical side wall 80b, and a top 80c. A tubular fitting 81 extends outwardly from the interior of the tank 80 and has the first conduit 16 connected thereto by conventional means as may be seen in FIG. 4. Air with entrained dust and particled foreign material from the automotive wheel support assembly B discharges through the fitting 81 and an opening 83 formed in the side wall 80b into the confined space 18. The top 80c supports a downwardly extending partition 82 formed from a rigid material, which partition has the lower end thereof situated below the surface of a body of water 85 that is situated in the tank 80 as shown in FIG. 4. The partition 82 has an opening 84 formed therein intermediate the top and bottom thereof, and the opening on each side having a vertically extending guide 86 that slidably engages a first vertically extending reach of an endless belt 88 formed from a screen. The endless belt 88 is rotatably supported on a transverse upper roller 90 and a transverse lower roller 92, with the upper roller being secured to a transverse first shaft 94 that has the ends thereof journaled in oppositely disposed portions of the side wall 80b. The lower roller 92 is mounted on a second transverse shaft 96 that has the ends thereof journaled in oppositely disposed portions of the side wall 80b. The longitudinal edges of the reach 88a of the endless belt 88 that is adjacently disposed to the partition 82 has the longitudinal edges of the reach slidably engaged by the guides 86. The first shaft 94 projects outwardly from the side wall 80b and has a first sprocket 98 mounted thereon. An endless chain belt 102 engages the first sprocket 98 and also a second sprocket 100. The second sprocket 100 is driven by a third electric motor 114 as may be seen in FIG. 4. A third transverse shaft is rotatably supported within the confined space 18 and is adjacently disposed to the second shaft 96. The third shaft 104 as shown in FIG. 4 supports a cylindrical brush 106 that rotatably pressure contacts the first reach 88a of endless screen belt 88, and the brush as it rotates serving to remove dust and foreign particled material from the belt and the dislodged material passing into the body of water 85. The third shaft 104 extends outwardly from the side wall 80b and has a third sprocket 108 mounted thereon, which sprocket engages a second endless chain belt 104 that extends upwardly to a fourth sprocket 110 mounted on the first shaft 94. When the third motor 114 is energized, the endless screen belt 88 is rotated as is the brush 106.
In FIG. 4 it will be seen that the invention A includes a water pump 115 that is driven by a fourth electric motor 116. The water pump 115 as may be seen in FIG. 4 has an inlet 118 which by a conduit 120 is connected to a strainer 122 situated within the confined space 18 adjacent the bottom 80a of tank 80. The strainer 122 is situated within the confines of a cylindrical screen 124 that extends upwardly from the bottom 80a. Pump 115 has a discharge outlet 126 that is connected to a conduit 128 that extends upwardly adjacent to the exterior of the tank 80 to communicate with a transverse header 130 that is intermediately disposed between the upper portion of the side wall 80b and the partition 82 as shown in FIG. 4. The header 130 has a number of transversely spaced downwardly extending nozzles in communication with the interior thereof, which nozzles direct sprays of water 133 downwardly over the reach 88a of the screen belt 88 as the belt moves downwardly past the opening 84 in the partition 82. The stream of air as it is drawn into the confined space 18 through the opening 83 due to the vacuum pump E maintaining a negative pressure in the confined space impinges on the screen 88 as it moves by the opening 84, and concurrently the sprays of water 85 are directed onto the screen to wash the incoming stream of air and separate dust and foreign particled material therefrom. The sprays of water tend to separate the dust and foreign particled material from the incoming stream of air and this dust and particled material being directed downwardly into the body of water 85. Dust or foreign material that adheres to the downwardly moving belt reach 88a is separated therefrom by the rotating brush 106. The body of water 85 is constantly recirculated through the invention a by the pump 115 as can be seen in FIG. 4. The tank 80 and the pump 115 with associated electric motor 116 are supported on a base 134 and the base in turn being movably supported on a number of rollers or casters 135. The tank 80 adjacent the bottom 88 is provided with a drain 137 through which water contaminated with dust and particled material may be discharged from the tank 80 when a valve 139 is opened as shown in FIG. 1.
The invention A as can be seen in FIG. 1 includes an inverted L-shaped tubular support 136 that has a horizontal rod 138 telescopically movable therein, with the rod on the free outer end portion thereof having a pivotal connection 140 from which a hook 142 depends. The hook 142 may removably engage the eye 40 as shown in FIG. 1 to support the hood C in a convenient position prior to the hood being secured to an automotive wheel support assembly B. The support 136 has a winch 144 mounted on an upper horizontal portion thereof which winch is manually actuated by use of a crank 146. The winch supports a cable 148 that extends downwardly over a roller 150 mounted on the free end of the horizontal portion of the support 136 and the cable on the downwardly extending end thereof having a hook 152 secured thereto. The hook 152 may removably engage an eye bolt 154 that extends upwardly from the vacuum pump E, and by use of the winch the top 80c the vacuum pump E and the motor 78 may be moved upwardly relative to the tank 80 to permit access to the interior thereof for cleansing purposes or the like.
The electric circuit used in actuating the invention A is shown in FIG. 5. A source of electric power 156 is provided that by a conductor 158 has one terminal thereof connected to a ground 160, and the other terminal of the source of electric power being connected to an electrical conductor 162. The electrical conductor 162 has junction points 162a, 162b, 162c and 162d therein. The junction points 162a, 162b, 162c and 162d are connected to first, second, third and fourth normally open electric switches 164, 166, 168, and 170. The first, second, third and fourth electric motors 50, 78, 114 and 116 have first terminals thereof connected by conductors 172 to ground 160. The first, second, third and fourth switches 164, 166, 168 and 170 include first, second, third and fourth contacts 164a, 166a, 168a and 170a that are electrically connected to second terminals of the first, second, third and fourth motors 50, 78, 114 and 116. When the first, second, third or fourth switches 164, 166, 168 or 170 are closed, the first, second, third and fourth electric motors 50, 78, 114 and 116 associated therewith are energized and the invention A is in an operating condition. To prevent rust the interior surface of the bottom 80a and the side wall 80b of tank 80 is preferably coated with a water impervious film of plastic 87 or the like. The level of the body of water 85 in the tank 80 is visually indicated by vertically movable rod 190 that is slidably supported by brackets 192 secured to the interior surface of the side wall 80b with the rod extending upwardly through an opening 194 in the top 80c of tank 80. The lower end of the rod 190 has a float 194 secured thereto and as the level of the body of water 85 in the tank varies the portion of the rod 190 extending upwardly above the top 80c will likewise vary, and visually indicate to the operator the quantity of water within the tank.
The use and operation of the invention is as follows. The invention A is moved adjacent the automotive wheel support assembly B, and the wheel removed from the assembly. The hood C is caused to slidably and sealingly engage the exterior surface of the backing plate 12 as shown in FIG. 2. The second, third and fourth electric switches 166, 168 and 170 are now closed to energize the second motor 78, third motor 114 and fourth motor 116. The second motor 78 drives the vacuum pump E, to drop a stream of air through the air scoops 14 over the automotive wheel support assembly B to dislodge dust and particled foreign material therefrom, due to the vacuum pump creating a negative pressure within the confined space 18 of the tank assembly D. The air stream with the entrained dust and particled material flows through the conduit 16 into the confined space 18 where it is subjected to the washing action of the sprays 85. The stream of air after being washed passes through the opening 84 and reach 88a of endless screen belt 88. Dust and foreign material impinge on reach 88a of belt 88 and are carried downwardly into the body of water 85 thereby, and remove from the belt by the rotating brush 106. The body of water 85 is continuously recirculated by the pump 126 to provide spray 85.
Air substantially free of dust and particled foreign material is withdrawn from the confined space 18 through conduit 20 by operation of pump E and discharged through conduit 22 to filter G. The filter G removes any remaining dust or particled foreign material from the stream of air, with the air then being discharged from the filter to the ambient atmosphere. From experience it has been found that some dust and particled material will not be dislodged from the interior of the brake shoes 10 by the stream of air drawn through the hood C. To dislodge such dust and particled foreign material the valve 68 is moved to the open position by use of handle 70. A strong jet of air discharges from the tubular member 54c onto the interior of brake shoes 10. The entire interior surface of the brake shoes may be subjected to such a jet by closing the first switch 164, with the first motor 50 now rotating tube 54 relative to brake shoes 10. The dust and particled foreign material dislodged by this jet of air is entrained with the stream of air that is concurrently being drawn into the confined space 18 through conduit 16.
After the dust and particled foreign material has been removed from the wheel support assembly B, the switches 164, 166, 168 and 170 are moved to the open position. The hood C is now removed from the backing plate 12, and disposed in a position to be supported from hook 142 as shown in FIG. 1 until again needed. The removed wheel (not shown) is now returned to its normal position on the wheel support assembly B. The above-described operation is sequentially performed on all of the wheel support assemblies of an automotive vehicle.
The use and operation of the invention has been explained previously in detail and need not be repeated. | A movable brake dust recovery unit that may be disposed adjacent an automotive shaft after the wheel has been removed therefrom, and thereafter subject the backing plate and associated brake shoe assemblies to a current of air to remove particled foreign material therefrom.The current of air with entrained dust and particled foreign material is directed into a confined space where the air is washed and then subjected to the action of a filter. The washed and filtered air may then be safely discharged to the ambient atmosphere without danger of contaminating the same. During the above-described operation the brake shoe assemblies and the interior of the brake drum are subjected to a rotating blast of air to separate dust and foreign material therefrom, with the separated dust and foreign material being subsequently entrained with a current of air and carried into the confined space. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a new and improved method for the manufacture of metallic alloys for use as preliminary materials, structural articles or components, workpieces or the like, composed of titanium-aluminum base alloys, wherein the melted starting materials are teemed into a mold and the cast element or casting is re-melted. Furthermore, the present invention relates to a new and improved arrangement or apparatus for the manufacture of metallic alloys, especially having an ordered crystal lattice, for use as preliminary materials, structural articles or components, workpieces or the like, composed of titanium-aluminum base alloys with a maximum of 40 to 60 atomic-% titanium and comprising a melting apparatus.
2. Discussion of the Background and Material Information
During the manufacture of titanium-aluminum (Ti-Al) base alloys extreme difficulties presently exist in achieving a sufficient ductility and workability or deformability of the fabricated alloy products or articles. In particular, the high gas content, especially the high oxygen content, of the alloys produced according to conventional techniques, pose difficulties and prevent the attainment of a high ductility and workability or deformability of the fabricated alloys or alloy products. The usual techniques considered acceptable by those skilled in this technology to melt such alloys from pulverulent starting materials and to produce such by an HIP-operation (hot isostatic pressing-operation), have not met with success.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind, it is a primary object of the present invention to provide an improved method and arrangement for the manufacture of metallic alloys composed of titanium-aluminum base alloys, in a manner not afflicted with the shortcomings and drawbacks of the prior art.
Another and more specific object of the present invention aims at the provision of an improved method and arrangement for the manufacture of metallic alloys composed of titanium-aluminum base alloys which possess good deformability, without the need to pulverize the starting materials.
Still a further noteworthy object of the present invention is the provision of an improved method and arrangement for the manufacture of metallic alloys composed of titanium-aluminum base alloys which can be produced in a relatively simple and economical fashion, especially by using starting material fragments or pieces.
Another important object of the present invention resides in devising an improved method and arrangement for the manufacture of metallic alloys composed of titanium-aluminum base alloys, wherein it is possible to quite accurately determine the alloy composition of the melt.
It has been completely surprisingly found that there can be manufactured alloy structural articles or components of good deformability if the alloy or alloying components or starting materials are made available or held in readiness in the form of pieces or fragments which essentially correspond in proportion to the alloy composition and are melted in a melting crucible, and the desired alloy composition containing a maximum of 40 to 60 atom-% titanium can be set or adjusted in the melting crucible by the alloying or addition of one or more, if necessary, further alloy components or constituents, and the melt from the melting crucible is cast into elements or articles, advantageously elongate or lengthwise extending blocks or bars or rods which are subsequently self-consumably remelted as an electrode of an arc-melting furnace, preferably in the presence of vacuum conditions, into a compact or dense element, in particular, a compact or dense block or preliminary material for structural articles or components.
The method of the present development affords the advantage that there can be dispensed with the need to pulverize the starting materials and advantageously there can be used as the starting materials fragments or pieces of pure metal and/or pieces of scrap and/or pieces of recycled scrap, in order to produce, as considered from the standpoint of alloying technology, homogeneous electrodes having low gas content. At the same time there can be, however, accomplished an exact setting or adjustment of the alloy composition of the melt, and there exist modest expenditures in the practice of the inventive method.
According to a preferred embodiment of the inventive method, it is contemplated to melt down the starting materials in a cooled metallic, melting crucible equipped with suitable melting means, such as at least one electrode rotating about its lengthwise or longitudinal axis, especially a water-cooled electrode formed of copper, titanium aluminum or an alloy or alloying component, or at least one plasma- or electron beam-melting apparatus, preferably in the presence of a protective gas at reduced pressure. As a result, there is realized an energy-saving melting of the pieces or fragments of the starting materials, without affecting the alloy composition, by an electrode formed of metals which do not adversely affect or influence the alloy properties. Furthermore, due to the employment of the arc or optionally the plasma or electron beam, there is realized a high localized application of energy, namely thermal energy and at the same time a completely homogeneous mixing of the alloy metals, that is, the realization of an orderly crystal arrangement.
According to a further aspect of the inventive method, the blocks or bars or the like, prior to the arc remelting operation, are subjected to a surface treatment or cleaning operation and/or a hot isostatic pressing operation.
Still further, the preliminary materials or elements obtained as a result of the arc melting operation, if necessary following a hot isostatic pressing operation, are subjected to thermal deformation or forming, especially for producing the desired end products.
Exceedingly good results are obtained if the oxygen content of the alloy due to the melting and re-melting, if necessary in conjunction with at least one HIP-operation, is set or adjusted to amount to less than 600 ppm, preferably less than 500 ppm.
An arrangement or apparatus for the manufacture of metallic alloys comprising titanium-aluminum base alloys, according to the present development, is manifested, among other things, by the features that the melting apparatus comprises a cooled metallic melting crucible, preferably formed of copper (Cu), for melting the pieces or fragments of the starting materials. There is used for such melting operation at least one cooled electrode rotating about its lengthwise axis and formed of copper, aluminum, titanium or an alloy component. Furthermore, there is arranged after or downstream of the melting apparatus, a vacuum arc-melting apparatus for the remelting of the castings or cast pieces obtained at a casting station by teeming the melt, received from the melting crucible, into preferably lengthwise extending or elongate molds. In this manner, there is provided a relatively simply constructed arrangement or assembly for the melting of titanium-aluminum base alloys, wherein the manufacture of the alloys can be rapidly accomplished and without enduring large transport paths or distances or energy losses.
A further aspect of the present invention, is the use of an apparatus, more specifically a melting apparatus which comprises a cooled, preferably a liquid-cooled, such as a water-cooled, metallic melting crucible and at least one electrode which extends into or can be inserted into the cooled, metallic melting crucible, wherein, this at least one electrode rotates about its lengthwise axis, is formed of copper, aluminum or titanium or an alloy component, and serves for the melting of pieces or fragments of starting materials for the fabrication of titanium-aluminum base alloys.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed single figure of the drawing depicting therein an exemplary embodiment of an arrangement or apparatus for the manufacture of titanium-aluminum base alloys.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawing, it is to be understood that only enough of the construction of the arrangement or apparatus for the manufacture of titanium-aluminum (Ti-Al) base alloys has been depicted therein, in order to simplify the illustration, as needed for those skilled in the art to readily understand the underlying principles and concepts of the present invention.
Turning now to the single drawing containing FIG. 1, reference character A designates a storage depot or area for fragments or pieces of starting material, for example, in the form of pure metals, pre-alloys, recycled scrap or the like. Specifically, there have been depicted at this storage depot or area A different components, for example, aluminum and/or aluminum-containing scrap 1, titanium and/or titanium-containing scrap 1' and/or chromium scrap and/or scrap 1" containing alloy or alloying constituents. The amounts of aluminum, titanium and possibly further desired alloying materials or constituents in the starting materials are well known to those skilled in this art, and the admixed starting materials in their aggregate or total approximately result in the desired composition of the alloy.
Continuing, reference character B designates a suitable apparatus for the cleaning of the surfaces of the starting materials. This cleaning apparatus B can comprise, for example, a sandblast unit or blower, a pickling apparatus or any equivalent or other suitable cleaning apparatus.
Reference character C generally designates a melting apparatus. This melting apparatus C comprises a charging chamber or compartment 2 equipped with a door 21 or the like affording access to a vibrating or jarring chute or trough S or equivalent structure. A delivery or feed device 11 introduces the starting materials, which may be possibly comminuted, either from the cleaning apparatus B or directly from the storage depot or area A onto the vibrating chute S. This vibrating chute S conveys the alloy constituents and/or the scrap into a melting crucible 35 which is preferably formed of copper and is appropriately liquid-cooled, for instance, water-cooled. Reference numeral 34 designates slag vats or receivers or the like which, if necessary, can be provided for the melting crucible 35 arranged in a melting chamber 3. An electrode or electrode member 36 can be introduced into the melting crucible 35 arranged in the melting chamber 3. This electrode 36 comprises a cooled, non-consumable electrode which rotates about its lengthwise axis. Any suitable drive can be provided for imparting such rotational movement to the rotatable electrode 36. The rotatable electrode 36 can be suitably mounted to be immersible into the melting crucible 35 and melts the alloy constituents and/or the scrap by forming an arc between the cooled surface of the rotatable electrode 36 and the scrap or molten bath formed in the melting crucible 35.
As also will be seen by further inspecting the single figure of the drawing, reference numeral 31 schematically designates an apparatus for the removal of samples and for the infeed of alloy or alloying constituents for the exact setting of the composition of the melt, reference numeral 32 schematically designates observation or viewing means for observing the melt within the melting crucible 35, and reference numeral 33 schematically designates a vacuum closure or the like provided for the charging chamber 2 which, if necessary, is or can be separated by a sluice 22 from the melting chamber 3.
The melting apparatus C furthermore comprises a casting station 4 within which there are arranged elongate or lengthwise extending molds 5 into which there is teemed the melt or molten bath delivered by the melting crucible 35. The molds 5 which, if necessary, may be pre-heated and/or are appropriately thermally insulated, are provided with an insulating hood or hood member 51, so that there are beneficially eliminated structural stresses and undesired crystallization phenomena.
The lengthwise extending cast products or articles, specifically the elongate blocks or bars 6 formed in the molds 5, are extensively homogeneous and, if necessary, can be delivered to a hot isostatic pressing or simply briefly termed HIP-apparatus D where such elongate blocks 6 or the like are exposed to hot isostatic pressing. Thereafter, at a downstream arranged suitable surface treatment or cleaning apparatus E, the elongate blocks or bars 6 can be subjected to a surface treatment or cleaning operation prior to delivery to a subsequently disposed vacuum-arc furnace F. In this vacuum-arc furnace F the elongate blocks or bars 6 are arranged as electrode blocks 6' in a furnace vessel 7 and remelted by an arc. The thus formed blocks or elements 8 are optionally delivered to a further HIP-apparatus G and thereafter to a deformation or working apparatus H where the blocks are hot-worked or hot-formed. Reference numeral 9 designates the outfeed or removal location where there are removed the finished-fabricated preliminary materials, articles or the like, for further use thereof.
It has been found that it is easily possible to obtain ductile and deformable alloy products having an oxygen content of less than 600 ppm. Without placing any particular requirements upon the starting materials and upon the vacuum-remelting or vacuum-arc furnace apparatus F and upon the melting apparatus C, there can be attained an oxygen content of less than 450 ppm, and a nitrogen content of less than 80 ppm and a hydrogen content of less than 6 ppm, and there is present extremely great alloy homogeneity.
In particular, the fabricated alloy structural articles or components also exhibited an appreciably improved hot-forming or thermal deformability in temperature ranges above 650° C. or 700° C., and these alloy properties or characteristics can not be achieved at all when employing powder-metallurgical manufacture.
While there are shown and described present preferred embodiments of the invention, it is distinctly to be understood the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. | The invention is directed to a Titanium-aluminum base alloy articles are produced from pieces of starting materials by melting thereof in a metallic melting crucible having a rotating electrode or a plasma- or electron beam device and there is then accomplished arc remelting, preferably vacuum-arc remelting following the melting of the pieces of starting materials. Furthermore, the arrangement for the manufacture of the articles formed of titanium-aluminum base alloys comprises a melting apparatus containing a rotating electrode or a plasma- or electron beam device and a vacuum-arc melting apparatus. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to injector guns for dispensing pastes, and more particularly, to injector guns that can dispense paste from a cartridge both at low pressure and high volume for filling a void and at high pressure and low volume for pressurizing the paste in the void. The present invention further includes means for connecting the injector gun to cartridges having different diameters.
Prior art injector guns have a trigger mechanism that includes a trigger in the form of a lever. The trigger includes an input end, an output end and a fulcrum between the ends. When the input end is squeezed by the user, the trigger pivots about the fulcrum causing the output end to move. The mechanical advantage of an injector gun is the amount the force applied to the input end is multiplied at the output end and can be calculated as the ratio of the length of the trigger from the fulcrum to the input end over the length of the trigger from the fulcrum to the output end. A high mechanical advantage multiplies the force more but generates less motion at the output end than does a low mechanical advantage. Therefore, a high mechanical advantage facilitates generating a high pressure in the paste but extrudes a low volume of paste whereas a low mechanical advantage generates a low pressure in the paste but extrudes a high volume of paste.
A typical application for paste injector guns is for dispensing bone cement from a cartridge into the intramedullary canal of the femur. Miller discloses such an injector gun in U.S. Pat. No. 4,338,925. Miller teaches the advantage of improved implant fixation that results from pressurizing the cement after filling the canal in order to force the cement into bony interstices. Therefore, Miller requires an injector gun with a relatively high mechanical advantage. However, as is typical of most injector guns, Miller's injector gun utilizes a trigger mechanism with a constant mechanical advantage that is a compromise between a low mechanical advantage that delivers a high flow rate for rapid filling and a high mechanical advantage that delivers high pressure for pressurizing the cement. To increase the flow of cement, the surgeon must squeeze the trigger faster. To increase the pressure on the cement, the surgeon must squeeze the trigger harder.
Some investigators have provided injector guns with user adjustable mechanical advantages. In U.S. Pat. No. 5,197,635, Chang teaches a mechanism that includes a bearing element that is adjustable up and down on the trigger and held in place by a set screw. By moving the bearing element, the output length of the trigger is changed and thus the mechanical advantage is changed. In U.S. Pat. No. 5,381,931, Chang teaches a different mechanism for selectively lengthening the output length of the trigger comprising an eccentric rotatable element attached to the output end of the trigger. Finally, in U.S. Pat. No. 5,431,654, Nic teaches a mechanism comprising two pawls attached to the trigger. The pawls are of a length and orientation such that one provides a high mechanical advantage and the other provides a low mechanical advantage. The desired pawl is engaged by means of a switch activated by the surgeon.
A disadvantage of prior art injector guns with user adjustable mechanical advantages is the need for additional parts and the resulting complexity in the trigger mechanism. Another disadvantage is the need to adjust a screw or move a switch in order to change the mechanical advantage. This adjustment typically requires both of the user's hands to effect the change. A further disadvantage of prior art cement injector guns is that they are configured to connect only to a cement cartridge having a single specified diameter. These prior art cement injector guns are therefore incapable of dispensing cement from differently sized cartridges such as from different manufacturers or different styles or sizes from the same manufacturer.
SUMMARY OF THE INVENTION
The present invention solves these problems of the prior art by providing a paste injector gun, especially adapted for injecting bone cement, having first and second mechanical advantages corresponding to different portions of the trigger stroke. The first mechanical advantage is greater than the second such that the first facilitates pressurizing the bone cement and the second facilitates high volume dispensing of the bone cement.
The two mechanical advantages are accomplished by providing a trigger mechanism with a trigger lever pivotably connected to a drive plate at the output end. The trigger mechanism includes two fulcrums which provide two sequential centers of rotation. In the initial position, the first fulcrum is engaged. As the trigger is squeezed, a high mechanical advantage enables cement pressurization because the first fulcrum is close to the output end of the trigger lever. At the end of this first stage of trigger travel, the second fulcrum is engaged. During the second stage of trigger travel, the trigger lever pivots about the second fulcrum. This results in a higher flow volume because the second pivot point is further from the output end of the trigger lever. With the present invention there are no screws or switches which must be adjusted to change mechanical advantage. The two mechanical advantages are designed into each squeeze of the trigger. The first portion of the trigger stroke produces high pressure and the second portion of the trigger stroke produces high flow volume. If high flow is desired, full strokes are used. If high pressure is desired, short strokes are used. The injector gun of the present invention also includes a pair of U-shaped slots for gripping a bone cement containing cartridge. One of the slots is sized to accept a large cement cartridge. The other slot is sized to accept a small cement cartridge.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side cross-sectional view of the cement injector gun of the present invention.
FIG. 2 is an end view of the cement injector gun of FIG. 1.
FIGS. 3-5 are side cross-sectional views of the trigger mechanism of the cement injector gun of FIG. 1 showing the operation of the trigger.
FIG. 6 is a side cross-sectional view of an alternative embodiment of the trigger mechanism of the cement injector gun of the present invention.
FIG. 7 is a side cross-sectional view of another alternative embodiment of the trigger mechanism of the cement injector gun of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 depict a cement injector gun according to the present invention. A shaft 1 is mounted for axial translation within a housing 2. The shaft includes teeth 3 formed on a portion of its circumference and along its length. A handle 4 is attached to one end of the shaft 1 and a shaft plate 5 is attached to the other end of the shaft 1. The shaft plate 5 contains a recess 6 in its back side. A spring loaded plunger 7 is mounted in the housing behind the shaft plate 5 such that when the teeth 3 are oriented downwardly, the plunger 7 is aligned with the recess 6. A drive plate 8 is mounted for axial translation within the housing 2 and is coaxial with and surrounds the shaft 1. A return spring 9 biases the drive plate 8 rearwardly in the housing. The drive plate 8 carries a drive ratchet 10 rotatably mounted on the drive plate 8. A spring biases the drive ratchet 10 into contact with the shaft 1 such that the drive ratchet 10 will engage the teeth 3 when they are oriented downwardly. A retaining ratchet 11 is rotatably mounted on the housing 2 and it is also spring biased into contact with the shaft 1 such that the retaining ratchet 11 will engage the teeth 3 when they are oriented downwardly. The injector gun includes a trigger having a trigger lever 12 pivotally attached to the drive plate 8 at the trigger lever's output end 13. The input end 14 of the trigger lever 12 extends from the housing 2. The trigger lever 12 also includes first and second beating portions 15 and 16. First and second fulcrums, 17 and 18, are attached to the housing 2 in alignment with the first and second bearing portions 15 and 16. In the embodiment shown in FIG. 1, the fulcrums are in the form of cylindrical pins attached to the housing and the being portions are in the form of scalloped regions formed on the trigger. A cartridge adapter 19 is mounted on the front of the housing 2. The cartridge adapter 19 contains first and second U-shaped slots, 20 and 21, lying on a common axis in axial alignment with the shaft 1. The U-shaped slots lie in parallel planes to one another. The second U-shaped slot 21 has a larger radius than the first U-shaped slot 20. The U-shaped slots are shaped to engage a cartridge 24 having a rim 25. Each U-shaped slot includes a peripheral groove 22 and 23 to engage the rim 25 to prevent the cartridge from moving forward as the shaft presses against the cartridge. The first U-shaped slot is at least 10% narrower, preferably at least 20% narrower than the second slot. Therefore, first U-shaped slot 20 is sized for a small cartridge and the second U-shaped slot 21 is sized for a large cartridge. The first U-shaped slot 20 is positioned on the common axis nearer to the trigger mechanism than the second U-shaped slot 21 such that a cartridge 24 engaged with the first U-shaped slot 20 will extend through the second U-shaped slot 21 and a cartridge engaged with the second U-shaped slot 21 will not extend through the first U-shaped slot 20.
Referring now to FIGS. 1-5, the function of the cement injector gun will be explained. In use the handle 4 is turned until the teeth 3 disengage the ratchets 10 and 11. The shaft 1 is then pulled backward until the plunger 7 is depressed and the shaft plate 5 is fully seated in the housing 2. The handle 4 is then rotated until the teeth 3 are in alignment with the ratchets 10 and 11. As the teeth 3 come into alignment with the ratchets 10 and 11, the recess 6 will come into alignment with the plunger 7 and the plunger 7 will pop out to extend into the recess 6. The popping of the plunger 7 into the recess 6 is thus an audible and tactile indicator of proper tooth-to-ratchet alignment. With the shaft 1 fully retracted, a cartridge 24 is slid into the appropriate slot, 20 or 21, of the cartridge adapter 19.
To dispense cement, the trigger is squeezed by applying pressure to the input end 14 of the trigger lever 12. The trigger has a range of rotation from the rest position shown in FIG. 3 to the stop position shown in FIG. 5. In the preferred embodiment, the range of rotation is divided into two stages. The first stage is from the initial rest position to an intermediate position where the center of rotation changes from the first fulcrum to the second fulcrum. The second stage is from this intermediate position to the stop position. During the first stage, the first bearing portion 15 contacts the first fulcrum 17 providing a first center of rotation. The trigger lever 12 pivots about the first fulcrum 17 causing the drive plate 8 and drive ratchet 10 to move forward. The drive ratchet 10 presses against the teeth 3 thus driving the shaft 1 forward as well. As the shaft moves forward, the retaining ratchet 11 pivots against its biasing spring and allows the teeth 3 to slip by it. The forward moving shaft plate 5 engages the cartridge 24 and forces cement from it.
Because the first fulcrum 17 is near the output end 13, the first mechanical advantage is relatively high and a small input force yields a large output force for driving the shaft forward. This high mechanical advantage allows a large amount of pressure to be generated in the cement to force cement into bony interstices. Corresponding to the high mechanical advantage is a small movement of the shaft equal to the distance between points A and B as shown in FIG. 4. This small shaft 1 movement dispenses a relatively low volume of cement. Preferably, the trigger lever 12 rotates about the first fulcrum 17 during the first 15° of trigger travel at which point it contacts the second fulcrum 18. During this first stage of trigger travel, corresponding to rotation about the first fulcrum 17, the shaft 1 preferably travels forward 2 teeth or a distance of about 0.1". The distance the shaft moves for each degree of trigger rotation about the first fulcrum is the first advancement rate.
During the second stage of trigger travel, the trigger lever 12 rotates about a second center of rotation provided by the second fulcrum 18 as shown in FIG. 5. Because the second fulcrum 18 is further from the output end 13, the second mechanical advantage is relatively low. Preferably, the second mechanical advantage is from 10% to 90% of the first mechanical advantage, more preferably 25% to 50%. Corresponding to this low mechanical advantage is a relatively large shaft movement corresponding to the distance between the points B and C. This large shaft movement dispenses a large volume of cement but less pressure can be generated in the cement from a particular input force because of the lower mechanical advantage. Preferably this second stage of trigger travel corresponds to approximately 20° of trigger lever 12 rotation and moves the shaft forward 6 teeth or a distance of about 0.3". The distance the shaft moves for each degree of trigger rotation about the second fulcrum is the second advancement rate. Preferably the second advancement rate is 1.1 to 10 times the first advancement rate, more preferably 2 to 4 times.
Thus two mechanical advantages are designed into each squeeze of the trigger. The first portion of the trigger stroke produces high pressure and the second portion of the trigger stroke produces high flow volume. If high flow is desired, full strokes are used. If high pressure is desired, short strokes are used. For a typical surgical procedure, full strokes would be used to fill a bone canal. Once the canal is filled, short strokes would be used to build fluid pressure in the cement in the bone canal.
FIGS. 6 and 7 depict alternative embodiments of the present invention. In FIG. 6, a trigger lever 30 includes two fulcrums 31 and 32 in the form of raised areas or bumps. A bearing member 33 is attached to the housing opposite the fulcrums 31 and 32. As the trigger lever 30 is squeezed, the first fulcrum 31 initially contacts the bearing member 33 and the trigger lever 30 rotates about the first fulcrum 31 during the first stage of trigger travel. During the second stage of trigger travel, the trigger lever 30 rotates about the second fulcrum 32. In FIG. 7, a trigger lever 40 includes a fiat beating portion 41. Two fulcrums 42 and 43, similar to those depicted in FIG. 1, are attached to the housing opposite the bearing portion 41. As the trigger lever 40 is squeezed, the bearing portion 41 initially contacts the first fulcrum 42 and the trigger lever 40 rotates about the first fulcrum 42 during the first stage of trigger travel. During the second stage of trigger travel, the trigger lever 40 rotates about the second fulcrum 43. The embodiments of FIGS. 6 and 7 provide the same function as the embodiment of FIG. 1. They provide a cement injector gun having a trigger mechanism with two stages of travel provided by two fulcrums that are engaged sequentially during the trigger stroke. The first stage is characterized by a high mechanical advantage for pressurizing the bone cement and the second stage is characterized by a low mechanical advantage for extruding a large volume of bone cement. The embodiments of FIGS. 6 and 7 differ from that of FIG. 1 only in the shape and placement of the fulcrums.
Other alternatives in the construction and use of the paste injector gun can be made as well. For example, additional trigger stages each with its own mechanical advantage could be incorporated so that there would be more than two stages. By doing this, the change in mechanical advantage could be made more gradual. Also, the benefits of the paste injector gun of this invention can be used advantageously for dispensing pastes other than bone cement. Finally, it will be understood by those skilled in the art that further variations in design and construction may be made to the preferred embodiment without departing from the spirit and scope of the invention defined by the appended claims. | A paste injector gun, especially adapted for injecting bone cement, has first and second mechanical advantages corresponding to different portions of the trigger stroke. The first mechanical advantage is greater than the second such that the first facilitates pressurizing the bone cement and the second facilitates high volume dispensing of the bone cement. The injector gun also includes a pair of U-shaped slots. One of the slots is sized to accept a large cement cartridge and the other slot is sized to accept a small cement cartridge. | 1 |
BACKGROUND INFORMATION
[0001] The present invention relates to magnetic hard disk drives. More specifically, the present invention relates to a system and method for preventing piezoelectric micro-actuator manufacturing and operational imperfections.
[0002] In the art today, different methods are utilized to improve recording density of hard disk drives. FIG. 1 provides an illustration of a typical drive arm configured to read from and write to a magnetic hard disk. Typically, voice-coil motors (VCM) 102 are used for controlling a hard drive's arm 104 motion across a magnetic hard disk 106 . Because of the inherent tolerance (dynamic play) that exists in the placement of a recording head 108 by a VCM 102 alone, micro-actuators 110 are now being utilized to ‘fine-tune’ head 108 placement, as is described in U.S. Pat. No. 6,198,606. A VCM 102 is utilized for course adjustment and the micro-actuator then corrects the placement on a much smaller scale to compensate for the VCM's 102 (with the arm 104 ) tolerance. This enables a smaller recordable track width, increasing the ‘tracks per inch’ (TPI) value of the hard drive (increased drive density).
[0003] [0003]FIG. 2 provides an illustration of a micro-actuator as used in the art. Typically, a slider 202 (containing a read/write magnetic head; not shown) is utilized for maintaining a prescribed flying height above the disk surface 106 (See FIG. 1). Micro-actuators may have flexible beams 204 connecting a support device 206 to a slider containment unit 208 enabling slider 202 motion independent of the drive arm 104 (See FIG. 1). An electromagnetic assembly or an electromagnetic/ferromagnetic assembly (not shown) may be utilized to provide minute adjustments in orientation/location of the slider/head 202 with respect to the arm 104 (See FIG. 1).
[0004] Utilizing actuation means such as piezoelectrics (see FIG. 3), problems such as electrical sparking and particulate-enabled shortage can exist. It is therefore desirable to have a system for component treatment that prevents the above-mentioned problems in addition to having other benefits.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] [0005]FIG. 1 provides an illustration of a drive arm configured to read from and write to a magnetic hard disk as used in the art.
[0006] [0006]FIG. 2 provides an illustration of a micro-actuator as used in the art.
[0007] [0007]FIG. 3 provides an illustration of a ‘U’-shaped micro-actuator utilizing multi-layered piezoelectric transducers (PZT) to provide slider actuation.
[0008] [0008]FIG. 4 illustrates a potential problem of particulate-enabled shorting between piezoelectric layers.
[0009] [0009]FIG. 5 illustrates various problems affecting PZT performance.
[0010] [0010]FIG. 6 provides a cross-section of the micro-actuator arms with the micro-actuators unseparated and a cross-section of a micro-actuator arm after micro-actuator separation.
[0011] [0011]FIG. 7 provides a cross-section of the micro-actuator arms with the micro-actuators unseparated and a cross-section of a micro-actuator arm after micro-actuator separation under principles of the present invention.
DETAILED DESCRIPTION
[0012] [0012]FIG. 3 provides an illustration of a ‘U’-shaped micro-actuator utilizing multi-layered piezoelectric transducers (PZT) to provide slider actuation. A slider (not shown) is attached between two arms 302 , 304 of the micro-actuator 301 at two connection points 306 , 308 . Layers 310 of PZT material, such as a piezoelectric ceramic material like lead zirconate titanate, are bonded to the outside of each arm (actuator finger) 302 , 304 . PZT material has an anisotropic structure whereby the charge separation between the positive and negative ions provides for electric dipole behavior. When a potential is applied across a poled piezoelectric material, Weiss domains increase their alignment proportional to the voltage, resulting in structural deformation (i.e. regional expansion/contraction) of the PZT material. As the PZT structures 310 bend (in unison), the arms 302 , 304 (which are bonded to the PZT structures 310 ), bend also, causing the slider (not shown) to adjust its position in relation to the micro-actuator 301 (for magnetic head fine adjustments).
[0013] [0013]FIG. 4 demonstrates a potential problem of particulate-enabled shorting between piezoelectric layers. During manufacture and/or drive operation, particles may be deposited, and particle(s) 404 may end up bridging conductive layers 406 . Relative humidity can cause the particle(s) to absorb moisture from the air, enabling electrical conduction between PZT layers. This short 404 in the piezoelectric structure 406 can prevent its normal operation, adversely affecting micro-actuator 402 performance.
[0014] [0014]FIG. 5 illustrates various problems affecting PZT performance. FIG. 5 a provides an image of a stray particle 504 bridging (and potentially shorting) piezoelectric layers 502 . As stated above, humidity can cause the particle 504 to absorb moisture and become electrically conductive. FIG. 5 b provides an image of damage caused by electrical arcing 506 between piezoelectric layers 508 . Under the right conditions of voltage and air humidity, electricity may arc between piezoelectric layers 508 , causing damage and deformation 506 . FIG. 5 c provides an image of ‘smearing’ 510 (and potentially shorting) between layers 512 . Smearing can occur during manufacture when the micro-actuators are cut for separation. (See FIGS. 6 and 7). Material of the different layers 512 is smeared across one another as the cutting tool passes over the surface exposed by cutting.
[0015] [0015]FIG. 6 provides a cross-section of the micro-actuator arms with the micro-actuators unseparated and a cross-section of a micro-actuator arm after micro-actuator separation. FIG. 6 a illustrates a cross-section 604 of a portion 602 of a micro-actuator block structure. The cross-section 604 illustrates alternating layers 628 of conductive material 622 and PZT (insulating) material 624 applied to-the micro-actuator. FIG. 6 b illustrates a cross-section 608 of a micro-actuator arm 606 after separating the micro-actuator 610 from others. Separation may be performed in one embodiment by mechanical means (e.g., a rotating wheel blade or a straight edge knife). Other embodiments involve electrical means for micro-actuator separation (e.g., electric sputtering or ion milling). Further, chemical means may be used (e.g., chemical vapor deposition (CVD)). Note that the sides of the micro-actuator arm (finger) 606 expose the piezoelectric layers, including the electrically-conductive layers 622 .
[0016] [0016]FIG. 7 provides a cross-section of the micro-actuator arms with the micro-acuators unseparated and a cross-section of a micro-actuator arm after micro-actuator separation and ending with conductive layer application under principles of the present invention. FIG. 7 a illustrates a cross-section 704 of a portion 702 of a micro-actuator block structure. FIG. 7 b illustrates a cross-section 708 of a micro-actuator arm 706 after separating the micro-actuator 710 from others. In one embodiment of the present invention, after a set of conductive strips (conductive material) 712 , such as gold, platinum or copper, are placed upon the micro-actuator arm 706 , a PZT layer (insulative layer) 714 is applied over and between the conductive strips 712 , physically and electrically isolating the conductive strips 712 . Another set of conductive strips 712 and a PZT layer 714 are applied and the process is repeated until the number of layers and/or thickness is appropriate for the micro-actuator's application and performance. In one embodiment, the last layer applied is the conductive strip 712 , followed by the placement of a bonding pad 716 upon the piezoelectric layers (and on opposite ends 717 of the micro-actuator finger 706 , see also FIG. 9). In one embodiment, four to six layers PZT layers are utilized (five to seven conductive layers).
[0017] In one embodiment, upon separation of the micro-actuators 710 , the PZT layers 714 physically isolate the conductive strips 712 from each other, and thus, prevent ‘smearing’ (and potential shorting). Further, the PZT layers 714 electrically insulate the sides of the piezoelectric layers, preventing ‘arcing’ damage and particulate contamination (electrical bridging/shorting).
[0018] [0018]FIG. 8 provides a cross-section of the micro-actuator arms with the micro-actuators unseparated and a cross-section of a micro-actuator arm after micro-actuator separation and ending with PZT layer application under principles of the present invention. FIG. 8 a illustrates a cross-section 804 of a portion 802 of a micro-actuator block structure. FIG. 8 b illustrates a cross-section 808 of a micro-actuator arm 806 after separating the micro-actuator 810 from others. In one embodiment of the present invention, after a set of conductive strips (conductive material) 812 , such as gold, platinum or copper, are placed upon the micro-actuator arm 806 , a PZT layer (insulative layer) 814 is applied over and between the conductive strips 812 , physically and electrically isolating the conductive strips 812 . Another set of conductive strips 812 and a PZT layer 814 are applied and the process is repeated until the number of layers and/or thickness is appropriate for the micro-actuator's application and performance. In one embodiment, the last layer applied is a PZT layer 815 . In one embodiment, the last PZT layer 815 provides a ‘window’ (gap in insulation) for the bonding pad 816 to be attached within. (See FIG. 8). In one embodiment, four to six PZT layers and four to six conductive layers are utilized.
[0019] In one embodiment, upon separation of the micro-actuators 810 , the PZT layers 814 , 815 physically isolate the conductive strips 812 from each other, and thus, prevent ‘smearing’ (and potential shorting). Further, the PZT layers 814 , 815 electrically insulate the sides of the piezoelectric layers, preventing ‘arcing’ damage and particulate contamination (electrical bridging/shorting)
[0020] [0020]FIG. 9 provides a cross-section of a finger of a micro-actuator under principles of the present invention. In an embodiment, a window 902 is provided in the last PZT layer of 915 to give a conduction path between the top conductive layer (strip) 904 and the bonding pad 906 .
[0021] Although several embodiments are specifically illustrated and described herein, it will be appreciated that modifications and variations of the present invention are covered by the above teachings and within the purview of the appended claims without departing from the spirit and intended scope of the invention. | A system and method for preventing operational and manufacturing imperfections in piezoelectric micro-actuators by physically and electrically isolating conductive layers of the piezoelectric material. | 8 |
OBJECT OF THE INVENTION
[0001] The present invention relates to a highway protection barrier, of the type called vehicle restraint barriers, such as safety barriers, parapets, impact attenuators, terminals and transitions, the barrier being made of a soft material, such as rubber or any other elastomeric material, and internally provided with elastic elements which in addition to providing the suitable rigidity to the barrier or fence being formed, allow twisting and damping in vehicle impacts.
[0002] As is evident, the highway protection barrier is provided for being located at the side or as a median of a road, or even as a means for demarcating areas to which access is prohibited, all of this for attenuating the consequences of accidents or impacts of vehicles which, by oversight or any other circumstance, uncontrollably go off the road.
[0003] The object of the invention is to provide a highway protection barrier in which the restraint in the impact of a vehicle is based on damping by buckling, thereby preventing abrupt impacts, which gives rise to a minimization of injuries for the occupants of the impacting vehicle itself as well as a minimization of damages of the vehicle itself.
BACKGROUND OF THE INVENTION
[0004] Vehicle restraint systems, such as protection barriers or fences known as “guardrails”, usually are made up of rigid elements which, upon receiving an impact, become permanently deformed, such that the impact per se is abrupt, due precisely to the rigidity of the fence or barrier, which not only entails serious damage to the vehicle, but also important injuries for the occupants of the vehicle itself.
[0005] Additionally, sometimes it is necessary for the driver of a vehicle to be warned that he/she has impacted against the barrier, since, for example, if the latter is made of independent elements or bollards, which are completely flexible, an impact because of an oversight or because of not seeing those barrier elements, it can damage the vehicle itself, and even permanently damage the elements or bollards because the latter are provided so that once the impact has stopped, they recover their original position of vertically, but if the driver does not realize it, he/she can drag the bollard with the vehicle, permanently damaging it, etc.
DESCRIPTION OF THE INVENTION
[0006] The highway protection barrier proposed herein has been designed to solve the aforementioned drawbacks, being based on a simple but effective solution.
[0007] More specifically, the barrier of the invention, is characterized in that it is made up of a soft body, such as rubber or any elastomeric material, preferably based on recycled tires, incorporating a plurality of elastic elements embedded within the body of the fence itself, which can be cylindrically configured bollards made of the same material as the body of the fence, such that those elastic elements internally include springs which, together with the element in which they are integrated, provide sufficient rigidity to the fence and additionally elasticity due to the nature of the material from which the whole assembly is made, whereby the impact against the mentioned fence not only absorbs the blow of the vehicle, but the inner and elastic elements (springs or bollards which these springs are part of) also become deformed, giving way in order to attenuate or catapult the vehicle impacting against the fence.
[0008] In an embodiment variant the barrier has the particularity of having a curved profile, the concavity of which is oriented inwardly, that curved profile equally affecting the inner elastic elements making up the damping means on impact against the fence or barrier.
[0009] That curved configuration of the body of the barrier provides a greater ability of absorbing the impact than when the body of the barrier and the inner elastic elements themselves are straight.
[0010] In said curved configuration of the barrier, the elastic elements can be formed by cylindrical bodies forming bollards and, embedded in the latter, helical springs, which can be interconnected by means of horizontal sheets thereby achieving an inner reinforcement of the assembly.
[0011] In another embodiment variant of the barrier with a curved configuration, the inner elements of the elastic elements are made up of metal strips, meshes or sheets, being able to have a rough surface for improving the grip of the elastomeric material, as well as the helical springs themselves, while in an embodiment alternative the inner elements are made up of vertical or horizontal rods, and always with the common factor that both the body of the barrier and the elastic damping elements have a curved profile for achieving greater absorption of the impacts.
[0012] Therefore, the described highway protection barrier, especially in its curved configuration, not only absorbs the blow of the vehicle upon impact against it because the latter is made of an elastic material such as rubber, but the inner elastic elements experience deformation, giving way together with the body of the barrier, achieving an attenuation-absorption of the vehicle impacting with the barrier, thereby preventing abrupt impacts, which in part attenuates injuries to the occupants of the impacted vehicle, even minimizing the damages to the vehicle itself.
[0013] The barrier is able to incorporate impact detection means for activating acoustic and/or light signaling elements.
[0014] In an embodiment variant, the body of the barrier can be formed by independent elements like bollards, within which there is incorporated a circuit to which impact detection means are associated through which means the warning signal is triggered, which can be made up of a pressure sensor or a device for detecting the change in inclination of the bollard, or any other similar conventional device, such that when contact of the vehicle with the circuit is detected, a warning signal is generated, being emitted through one or more speakers or similar elements, also being able to activate the turning on of light indicators suitably arranged on the fence in question and/or even in the same device in the event that the latter is long enough to enable being seen from the driver's position.
[0015] In this embodiment variant, the acoustic/light signaling circuit does not have to be integrated in the bollard itself, but it can be arranged outside the latter, such that only a single acoustic/light signaling circuit is necessary for a group of bollards near each other, for which purpose it has been provided that the circuit associated with the impact detection means arranged in each bollard can be associated with a radio frequency emitting device of any type emitting an activation signal to activate the acoustic/light signaling circuit, in which case said circuit will incorporate the corresponding radio frequency receiver module through which the corresponding signal will be activated.
[0016] A system is thus achieved which allows automatically and unequivocally warning drivers of the possible collision of their vehicle against a bollard, preventing damages to both the vehicle and the bollard.
DESCRIPTION OF THE DRAWINGS
[0017] To complement the description that will be provided below and for the purpose of aiding to better understand the features of the invention according to a preferred practical embodiment thereof, a set of drawings is attached as an integral part of said description in which the following has been depicted with an illustrative and non-limiting character:
[0018] FIG. 1 shows a general perspective view of a highway protection barrier in a preferred embodiment of the invention.
[0019] FIG. 2 shows a sectional view of the barrier depicted in the previous figure, accordingly depicted with one of the inner elastic elements.
[0020] FIG. 3 shows another sectional view of the barrier depicted in the previous figure, showing the deformation that said barrier experiences and the corresponding inner elastic element, after the impact, with recovery after this latter.
[0021] FIG. 4 shows a depiction corresponding to a side perspective view of a portion of protection barrier object of the invention in an embodiment variant in which the body of the barrier and the inner elastic element are integral.
[0022] FIG. 5 shows a cross-sectional view of the barrier part depicted in the previous figure.
[0023] FIG. 6 shows a perspective view like that of FIG. 4 , where the inner elements of the elastic elements are sheets.
[0024] FIG. 7 shows a longitudinal sectional view of the barrier portion or sector depicted in the previous figure.
[0025] FIG. 8 shows a perspective view of the same barrier with a curved configuration depicted in FIGS. 4 and 6 , but in this case with the inner elements of the elastic elements made up of rods.
[0026] FIG. 9 shows a longitudinal sectional view of the sector of barrier depicted in the previous figure.
[0027] FIG. 10 shows a perspective view of a barrier sector or portion incorporating a string of LED type lights inserted in its projecting longitudinal part.
[0028] FIG. 11 shows a block diagram of the circuit for the highway protection barrier object of protection, and specifically in a bollard when said barrier is formed by independent elements or bollards per se.
[0029] FIG. 12 shows an embodiment variant of the circuit shown in the previous figure, in which the circuit generating acoustics/light signals is independent of the impact detection circuit, allowing the use of a single circuit generating acoustic/light signals for several independent barrier elements located close to each other.
PREFERRED EMBODIMENT OF THE INVENTION
[0030] As can be seen in the mentioned figures, in and specifically in relation with FIGS. 1 , 2 and 3 , the barrier of the invention is made up of a body ( 1 ) of soft material, such as rubber from recycled tires or other materials, incorporating within a plurality of elastic elements ( 2 ) which can be made up of cylindrical bollards, also made of soft material, i.e. rubber or the like, where damping ( 4 ) elastic ( 2 ) elements will be embedded within that cylindrical bollard or body, such that the fence is fixed, i.e., the body ( 1 ) forming it, by any suitable system on the ground, when it receives the impact of an automotive vehicle, an elastic deformation of the body ( 1 ) of the barrier itself, and therefore of the corresponding elastic elements ( 2 - 3 ), will occur, as seen in FIG. 3 , which corresponds to the deformation which the barrier with the elastic element housed within the body thereof experiences once a vehicle impacts it.
[0031] Due to the nature of the materials, the barrier is not permanently deformed given vehicle impacts, just as the elastic elements ( 2 ) with the cylindrical body ( 3 ) in which they are housed, but they recover their initial position when the blows are not too strong, further absorbing the impact and attenuating the blow.
[0032] Therefore, the barrier in question is formed by a body ( 1 ) which is solid and made of a soft material, i.e., elastomeric, such as rubber or the like, preferably obtained from the reuse or recycling of tires, and where the cylindrical elements ( 3 ) like bollards, incorporating the elastic elements ( 2 ) embedded within, will also be solid, together forming a barrier that is initially rigid but deformable in vehicle impacts, with the particularity that those elastic elements ( 2 ) can be embedded directly in the body ( 1 ) of the barrier, without needing the cylindrical bodies ( 3 ).
[0033] FIGS. 4 to 10 inclusive show an embodiment variant in which the body ( 1 ′) of soft material making up the barrier has a bent over configuration, with the concavity oriented inwardly, incorporating within the corresponding elastic elements ( 2 ′) housed in a body ( 3 ′) embedded within the body of soft material ( 1 ′), as in the previous cases, what happens in this case is the elastic elements ( 2 ′- 3 ′) are also curved according to the trajectory of the body ( 1 ′) of the barrier.
[0034] Instead of springs ( 2 ′) as is depicted in FIGS. 4 and 5 , such inner elastic elements can be made up of sheets ( 4 ) like strips or leaf springs, also with the same curved profile, making up, as in all the previous cases, damping means for a vehicle impact.
[0035] In another embodiment variant, the elastic elements are made up of rods ( 5 ) as shown in FIGS. 8 and 9 , also with the curved configuration of the body ( 1 ′) of the barrier, according to the curvature of the latter.
[0036] In another embodiment variant shown in FIG. 10 , the barrier or body ( 1 ′) thereof, is able to incorporate within motion sensors ( 7 ) which, after an impact, emit a warning by radio frequency or cable to LED type lights ( 6 ) incorporated in the same body of the barrier ( 1 ′), warning of an impact.
[0037] Likewise, the described highway safety barrier, in any of its embodiments, can serve to support conventional safety barriers, replacing the rigid metal posts holding the protective metal sheets or profiles.
[0038] Instead of being a body with an indefinite length, as depicted in the previously mentioned figures, the barrier can be formed by independent elements and in each of them an elastic element, forming a type of bollard in each case of the type used in urban areas to serve as a barrier preventing or warning that the established line of bollards cannot be trespassed.
[0039] In any case, those independent elements include a control circuit ( 8 ) associated with a power source ( 9 ), preferably connected to the power grid, although it could be supported by a rechargeable battery associated with a photovoltaic solar panel or any other conventional independent power solution.
[0040] An impact detection device ( 10 ) is associated with said control circuit, through which device ( 10 ) a warning signal is triggered, said impact detection device being able to consist of a pressure sensor such as that mentioned for FIG. 10 , or such as, for example, by means of a pendulum ( 11 ) shown in FIGS. 11 and 12 , which forms an electric conductor element remaining isolated from the corresponding contacts ( 12 ) in the upright or vertical position of the elastic element or bollard in question, whereas when this latter changes position, i.e., it is inclined due to an impact or the pressure of the body of a vehicle thereon, the pendulum ( 11 ) tends to be arranged in the vertical position due to the effect of gravity, coming into contact with one of the contacts, closing the electric control circuit and the latter generating an acoustic warning signal through one or more speakers ( 13 ) or light indicators ( 14 ) which would be equivalent to the LEDs ( 6 ) provided in the embodiment shown in FIG. 10 .
[0041] The control circuit assembly with all the mentioned components can be integrated within the casing or body of the protection barrier, or bollard per se, as depicted in FIG. 11 , or the acoustic and/or light signaling elements could be arranged externally and independently to save in costs, such as for example in a post or integrated in any urban fixture element, being able to be used for the acoustic signaling due to the impact of multiple elements or bollards forming the barrier and having reference numbers ( 15 , 15 ′ and 15 ″), the number of the latter being able to be greater.
[0042] In said case, the control circuit ( 8 ) will be associated with a radio frequency emitter ( 16 ) of any type existing on the market, which in the event of a blow to the barrier or bollard element ( 15 ) will generate a signal ( 17 ) that will be received by a radio frequency receiver module ( 18 ) which is associated with a control sub-circuit ( 8 ′) supported by the corresponding power source ( 9 ′) through which the warning signals through the speakers ( 13 ′) and light indicators ( 14 ′) are activated. | The barrier is formed by a solid body of soft material ( 1, 1 ′) with, embedded within, a series of elastic elements ( 2, 2′, 4, 5 ) that can be embedded directly in the body (V) or embedded within elements ( 3, 3 ′) of a soft material like that of the body ( 1, 1 ′), forming a type of bollard inside said body ( 1, 1 ′). The internal elastic elements may be constituted by helical springs ( 2, 2 ′), bands ( 4 ) or rods ( 5 ) and, in any event, the body ( 1 ) is capable of being bent over, following the same bend as the internal elastic elements ( 2 - 3′, 4 - 3 ′ and 5 - 3 ′). | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to a cantilever structure of mounting frame, more particularly a cantilever structure composed of an elastic element coupled with arc-shaped through-slot members.
BACKGROUND OF THE INVENTION
[0002] The dawning of digital age, prevalence of the Internet, and changes of digital broadcast signals have fueled the significant evolvement of display technology. Flat panel display (FPD) monitors offer the advantages of lightweight, thin form, power saving and free of radiation. It is expected to become the mainstream choice for computer monitor and home television.
[0003] Generally a stand is needed for the placement of FPD monitor on a desk for support and fixation or the adjustment of monitor angle.
[0004] In recent ears. FPD monitor stand and FPD arc commonly separately fabricated and then assembled. When a stand-included FPD monitor is placed on a desk, it is also easy to adjust the tilting angles of the LCD.
[0005] Because of poor mechanical design, mounts of prior art for display monitor are at times over-loaded or tend to displace after angle adjustment, resulting in a situation where the adjusted angle is not what the user desires. The present invention aims to address this drawback of display mount.
SUMMARY OF THE INVENTION
[0006] The invention relates to a cantilever structure of mounting frame that uses mainly the arc tracks of a first through-slot member and a second through-slot member on a flange to produce different tensile elongations of the elastic element such that the mounting frame can stay firmly at the adjusted position under the bearing created by different angles.
[0007] The invention comprises a holder in block configuration, the holder being extended on the same face with a first flange and a second flange paired and parallelly adjacent to each other, a first space member being situated between the first flange and the second flange, the first flange and the second flange being respectively configured with a first axle hole, a second axle hole, a first through-slot member and a second through-slot member; a cantilever assembly consisting of a first arm and a second arm, the first arm and the second arm having a Π-shaped long plate configuration and forming a hollow configuration when adjoined together, the first arm and the second arm also having on the same side respectively a third axle hole, a fourth axle hole, a third through-slot member and a fourth through-slot member, wherein the first axle hole can be coaxially coupled to the third axle hole, the second axle hole can be coaxially coupled to the fourth axle hole, the first through-slot member can be coupled to the third through-slot member, and the second through-slot member can be coupled to the fourth through-slot member, and the first through-slot member, the second through-slot member, the third through-slot member, and the fourth through-slot member can be assembled together with the insertion of a latch shaft: and an elastic element which is a spring and disposed between the first arm and the second arm, one end of the elastic element being attached to the latch shaft and the other end of the elastic element being attached to the same other end of the first space member as the first arm and the second arm such that the mounting frame can stay firmly at the adjusted position under the bearing created by different angles.
[0008] The objects, features and effects of the invention are described in detail below with embodiments in reference to the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is an exploded view of a preferred embodiment of the invention;
[0010] FIG. 2 is an action diagram 1 of the preferred embodiment of the invention;
[0011] FIG. 3 is an action diagram 2 of the preferred embodiment of the invention;
[0012] FIG. 4 is an action diagram 3 of the preferred embodiment of the invention; and
[0013] FIG. 5 is side view of the preferred embodiment of the invention added with a mount structure and an external shell.
DETAILED DESCRIPTION OF THE INVENTION
[0014] FIG. 1 is an exploded view of a preferred embodiment of the invention. The invention relates to a cantilever structure of mounting frame, comprising mainly of a holder ( 10 ), a cantilever assembly ( 20 ), an adjusting structure ( 30 ), and an elastic element ( 40 ). The embodiment is described in details below.
[0015] The holder ( 10 ) has a block configuration and is extended on the same face with a first flange ( 11 ) and a second flange ( 12 ) paired and parallelly adjacent to each other, a first space member ( 13 ) being situated between the first flange ( 11 ) and the second flange ( 12 ) the first flange ( 11 ) and the second flange ( 12 ) being respectively configured with a first axle hole ( 14 ), a second axle hole ( 15 ), a first through-slot member ( 16 ) and a second through-slot member ( 17 ), and the first through-slot member ( 16 ) and the second through-slot member ( 17 ) having mainly an arc-shaped configuration.
[0016] The cantilever assembly ( 20 ) consists of a first arm ( 21 ) and a second arm ( 22 ), the first arm ( 21 ) and the second arm ( 22 ) having mainly a Π-shaped long plate configuration such that a hollow configuration is formed when the first arm ( 21 ) and the second arm ( 22 ) are adjoined together, the first arm ( 21 ) and the second arm ( 22 ) also having on the same side respectively a third axle hole ( 23 ), a fourth axle hole ( 24 ), a third through-slot member ( 25 ) and a fourth through-slot member ( 26 ), wherein the first axle hole ( 14 ) can be coaxially pinpointed to the third axle hole ( 23 ), the second axle hole ( 15 ) can be coaxially pin-jointed to the fourth axle hole ( 24 ), the first through-slot member ( 16 ) can be coupled to the third through-slot member ( 25 ), and the second through-slot member ( 17 ) can oe coupled to the fourth through-slot member ( 26 ), and the first through-slot member ( 16 ), the second through-slot member ( 17 ), the third through-slot member ( 25 ), and the fourth through-slot member ( 26 ) can be assembled together with the insertion of a latch shaft ( 50 ).
[0017] The adjusting structure ( 30 ) consists of an adjusting screw ( 32 ) and an adjusting block ( 34 ), the adjusting screw ( 32 ) comprising a nut member ( 320 ) and a screw thread member ( 322 ), the nut member ( 320 ) of the adjusting screw ( 32 ) being arranged on the external surface of the cantilever assembly ( 20 ), the screw thread member ( 322 ) of the adjusting screw ( 32 ) penetrating through the cantilever assembly ( 20 ) and threading through one end of the adjusting block ( 34 ).
[0018] The elastic element ( 40 ) is a spring and disposed in a hollow space formed after the first arm ( 21 ) and the second arm ( 22 ) are assembled, one end of the elastic element ( 40 ) being attached to the latch shaft ( 50 ) situated in the first space member ( 13 ) and the other end of the elastic element ( 40 ) being attached to the other end of the adjusting block ( 34 ) such that turning the adjusting screw ( 32 ) will adjust the bearing force the elastic element ( 40 ) is subject to.
[0019] Referring to FIGS. 2 , 3 , 4 and 5 , FIG. 2 is an action diagram 1 of the preferred embodiment of the invention; FIG. 3 is an action diagram 2 of the preferred embodiment of the invention; FIG. 4 is an action diagram 3 of the preferred embodiment of the invention: and FIG. 5 is side view of the preferred embodiment of the invention added with a mount structure and an external shell. As shown, the assembled mounting frame can be coupled with a mount structure ( 60 ) and covered by a shell ( 27 ) over the cantilever assembly ( 20 ) to make it more aesthetic. The mount structure ( 60 ) hangs primarily a display device (not shown in the figure). First of all, the adjusting screw ( 32 ) is turned to adjust the restoring force of the elastic element ( 40 ) to proper magnitude. When the cantilever assembly ( 20 ) turns under an external force, it will turn around the fourth axle hole ( 24 ) (the first axle hole ( 14 ), the second axle hole ( 15 ), the third axle hole ( 23 ), and the fourth axle hole ( 24 ) have the same axle center), where the latch shaft ( 50 ) will move along with the location of space appeared as the second through-slot member ( 17 ) and the fourth through-slot member ( 26 ) overlap (similarly along with the location of space appeared as the first through-slot member ( 16 ) and the third through-slot member ( 25 ) overlaps), which at the same time changes the tensile elongation of the elastic element ( 40 ) where different restoring force is accumulated on the elastic element ( 40 ) such that when the external force is removed, the weight of the display device hung on the mount structure ( 60 ) can be offset by the restoring force provided by the elastic element ( 40 ) and the frictional force arising from the pin-jointed assembly of the first axle hole ( 14 ), the second axle hole ( 15 ), the third axle hole ( 23 ), and the fourth axle hole ( 24 ). As such, after external force is removed, the display device hung on the mount structure ( 60 ) will not produce extra displacement.
[0020] The cantilever structure of mounting frame provided by the invention achieves the objects of the invention using an elastic element coupled with arc-shaped through-slots. Thus the invention possesses inventiveness and meets the essential criteria for a patent.
[0021] The preferred embodiments of the present invention have been disclosed in the examples. However the examples should not be construed as a limitation on the actual applicable scope of the invention, and as such, all modifications and alterations without departing from the spirits of the invention and appended claims shall remain within the protected scope and claims of the invention. | The present invention relates to a cantilever structure of mounting frame that uses mainly the arc tracks of a first through-slot member and a second through-slot member on a flange to produce different tensile elongations of the elastic element such that the mounting frame can stay firmly at the adjusted position under the bearing created by different angles. | 5 |
TECHNOLOGY FIELD
The present ink relates in general to inkjet inks and in particular to inks suitable for printing on glass and ceramic substrates.
BACKGROUND
Inkjet printing on glass or ceramic substrates has been known for some time. The printing process includes the distribution of ink containing inorganic pigment particles, solvents, sub-micron glass frit particles, and some other ink ingredients across a surface of a substrate. The sub-micron glass particles and inorganic pigments are later fused or fired into the substrate during the tempering or annealing process. The fusing of ink into the substrate supports the creation of vivid, durable designs that can last as long as the substrate itself.
The inks used for ceramic tile decoration have to satisfy several criteria. First, they must have the correct rheological and other properties such that they can be easy ejected from the nozzles of the inkjet printhead. The inks printed on a glass or ceramic substrate have to produce the desired final gloss, color and stability after application to the substrate and its further thermal processing and in particular firing.
Most of the currently used inks contain finely ground refractory inorganic pigments, synthetic nanoparticles, or soluble metal compounds. The formulation of inks for inkjet printing is challenging because not only must the ink maintain the desired final appearance, but it also has to maintain the physical properties that have been specially optimized for ink-jet printing. For example, the inks for printing on glass or ceramic surface have to utilize inorganic pigments, be sufficiently opaque, and may contain their own binder in the form of a glass frit. Because of these considerations they usually have a higher solids load then for example, ink for printing on paper. In order to avoid nozzle clogging, the pigment and glass frit particles are usually of sub-micron size. In the long term, such particle dispersions become not stable and tend to form sediments changing the density or the printed image and to some extent its color. Therefore, printers are required to include expensive and complex systems for constantly agitating and circulating the ink to prevent its separation.
Inkjet printing on glass or ceramic surfaces is an industrial glass and ceramics decoration process and maintenance of a stable ink and proper operating printer are paramount for successful penetration of the technology into the mainstream glass and ceramics industrial printing processes. In order to achieve optimal results the inkjet ink formulations have also to be matched to existing inkjet printheads. The industry would welcome improvements of the existing ink formulations as well as development of new inkjet ink formulations.
BRIEF SUMMARY
The current document discloses an inkjet ink that is characterized by an exceptionally low sedimentation rate of glass frit and pigment particles. Practically, the ink reversibly gels upon extended standing, thus preventing sedimentation entirely. The ink includes a solvent or a mix of solvents and a glass frit. The ink composition includes a mixture of two glass frits, which could be a bismuth based glass frit and a zinc additive glass frit. The mixture of the glass frits includes particles of two sizes; small size particles 0.3-0.8 microns and large particles with size of 0.8 microns and up to 2.0 microns. The density of the solvent and the glass frit are selected such that the difference between their densities is small. For example, the solvents used have density exceeding 1.10 g/cc. The solvent chosen also has a high viscosity as far as possible while allowing for suitable ink properties. The ratio between the pigment particles and glass frit particles would typically be at least 1:1 to 1:3.
The glass frit, and in particular the one resulting in small size particles of 0.3-0.8 microns, is milled in presence of a controlled flocculation dispersant. Such dispersant could be for example, BYK-220S. The small size glass frit particles with sized of 0.3-0.8 microns support increase in gloss, opacity, and/or pigment loading of the final ink layer. Small size glass frit particles and in particular zinc-based glass frit particle reduce three fold particles sedimentation rate. The ink also includes anti-settling additives such as BYK-410, BYK-415 and BYK-430.
BRIEF LIST OF FIGURES AND THEIR DESCRIPTION
FIG. 1 demonstrates the relation between the milling time and particle size.
FIG. 2 is a plot that demonstrates a linear relationship between particle size and amount of settling.
DETAILED DESCRIPTION
As it was indicated above, inkjet inks for printing on glass and ceramics should have consistent properties within the required specification. Variation in any parameter could affect color intensity and definition (and therefore quality). One aspect to maintaining the density, viscosity and surface tension parameters of inks is keeping them at a constant temperature. This is desired in all cases, including pigment particle suspensions and organometallic compounds both for organic solvents and water. In some printers the entire ink reservoirs are kept at a constant temperature whereas in others just the small nozzle chambers or only the nozzles themselves. In some printers inks are continuously stirred and flow in a cycle from the main reservoir to the small chambers (and nozzles in some cases) and back to the main reservoir again. Operation of some printers includes a washing procedure and steps are scheduled, all without any break in the printing process. Therefore, stable inks with consistent properties are highly desirable.
Ceramic inkjet inks contain large amounts of particulate solids, including pigments and glass frit. These particulate components tend to aggregate and/or settle upon standing, leading to print inhomogeneity and even to system blockages. If settling or separation takes place during the ink drying process, then it can adversely affect the final product appearance, for example in terms of homogeneity or reproducibility. For these reasons, inkjet printers for inks containing particulate materials, such as inks for printing on glass or ceramic materials, generally include systems for ink circulation and agitation to prevent these problems. In addition, regular flushing of the print head could be used to ensure that stagnant ink does not cause problems in the print head. These requirements necessarily result in hardware and maintenance cost, as well as ink wastage. Therefore, the industry would welcome inks with low sedimentation rate that either reduce or remove the need for these systems.
Inkjet printing results in thin ink layers relative to other printing technologies such as screen-printing. Thicker ink layers can be produced by multiple passes over the same area, but this approach requires an investment in both (i) time and (ii) ink, as well as increasing the probability of ink bleed. Therefore, it is advantageous for inkjet inks to have a high pigment loading to provide high opacity in a thin ink layer. However, in order to provide adequate scratch resistance, pigment must be bound and encapsulated by frit. Sufficient frit must be used, and the total solids content of the ink must remain at a printable level. The binding effectiveness of the frit thus provides a limit on the amount of pigment that can be used in an ink. Therefore, inks supporting high pigment load are required by the industry.
A high loading of particles in the ink is preferred for the purpose of maximizing properties such as opacity and scratch-resistance. However, high particle loadings result in problems such as the clogging of fine channels and high viscosity. The use of low viscosity solvents is a typical way to keep the ink moving as freely and with as low a viscosity as possible.
Opacity relates to the ability to block light from passing into one side of the coating and out of the other. It is a key property of many coatings, for example where ink is used to mask unsightly or light-sensitive parts. Ceramic inkjet inks are often of low opacity by comparison with competing printing technologies, on account of the thin ink layer produced. As with pigment loading, low opacity can be addressed by resorting to thick ink layers, but this brings the drawbacks already discussed. Nevertheless, inks providing higher opacity of the printed layer would be preferred by the industry.
In addition, inks are often specified to have high gloss. Gloss is desirable not only from an aesthetic point of view, but also because it indicates a highly flat and non-porous surface, which is more resistant to staining, marking and chemical damage than matte surfaces are.
After ceramic ink has been applied to a substrate, the whole structure must be fired in order to sinter the ink and develop the final enamel. This process requires a certain combination of temperature and time, and the lower the requirements, the larger the number of applications that may be addressed. However, the development of frit formulations that have low firing requirements while also maintaining a high chemical stability, is extremely difficult, and so some compromise has to be made between the firing time/temperature and other properties.
Finally, ink production cost is a crucial issue for the successful development of economically viable inkjet ink. For ceramic inkjet inks containing significant quantities of finely-ground glass frit, this frit represents a major contribution—often the most major contribution—to the ink production cost. Therefore, a technology that allows the lowering of frit cost or content is highly desirable.
These and other problems could be resolved by selecting proper size glass frit particles, introduction of dispersants that control flocculation, using anti-sagging and anti-settling additives, introduction of ink ingredients reducing gelation upon standing, use of a relatively high viscosity vehicle, and minimization of density between liquid and solid ink ingredients mismatch.
Small Frit Particle Size
Glass frit is one of the major components of ceramic inks. The function of the glass frit is to bind pigment particles and to fuse with the substrate material to produce a strong and continuous structure. The frit particles must be small enough to provide visible homogeneity for the final fired ink (for example, smaller than 20 microns), and are generally milled no smaller than necessary size on account of the greatly increased cost incurred when milling particles to ever smaller sizes. Thus, frit particle size is in general determined by the requirements of the printing technology. In the case of screen-printing technology, where particles must only pass through the screen and settling is easily managed on account of the high ink viscosity, relatively high particle sizes are used—easily achieved e.g. by the cost-effective process of jet-milling. In inkjet inks however, it is necessary for particles to be sufficiently small to deposit by jetting through small orifices. Thus, particle sizes of less than 3 microns, and more often less than 1 micron are used. In order to keep these particles suspended in the ink during printer operation, circulation and agitation mechanisms are used. Therefore, the particle dispersions for such printers need only to be jettable, and not to be non-sedimenting.
Theory suggests that particle settling rate is proportional to particle size, and therefore smaller particles settle more slowly than larger ones. In addition, Brownian motion and internal dispersion structure dictate that below a certain particle size, settling may be inhibited completely. Such inhibition of settling can afford an advantage to printer construction in that agitation mechanisms will be unnecessary. All the same, very small frit sizes are avoided on account of the high cost of production and the high viscosity of such dispersions (viscosity rises significantly with decreasing particle size, and inkjet inks must have a low viscosity, usually in the range 5-50 cP).
Particle size in milled frits is generally measured by light scattering apparatus such as those developed and marketed by Malvern Instruments Ltd., Malvern WR14 1XZ United Kingdom or by Fritsch Laboratory Instruments GmbH, 55743 Idar-Oberstein Germany. These instruments make an indirect measurement based on the analysis of light scattering patterns while the particles are suspended in liquid vehicles. Other possibilities exist for particle size measurement, such as the individual measurement and counting of particles under SEM examination. Larger particle sizes can be determined by sieving. Milling produces a particle size and shape distribution rather than a population of particles with identical size and shape. However, in the field of inkjet inks, the term “particle size” is commonly understood to mean the average size of the particles as reported by a light scattering instrument. For the purposes of the present work, a Frisch Analysette 22 instrument is used, employing a Fraunhofer analysis, and the average particle size is reported as the D50 (the median particle diameter by mass; MMD). For the suspensions discussed, the D50 typically varies insignificantly from the D(4,3), which is another widely used definition of average particle size.
The present disclosed involves the milling of frit particles to a much smaller size than is typically used in ceramic inkjet inks, specifically to an average size in the range 0.3-0.8 microns. As well as the inhibition of settling, this particle size provides unexpected advantages in terms of the gloss, opacity, and pigment loading in inks, which in turn allow lower cost (because of reduced frit usage) and the possibility of improved printing (for example by allowing reduced wet ink thickness or lower total particle content).
According to the disclosure, frit milled to a very small particle size imparts gloss and opacity to an ink, while also reducing the total frit content required. A balance of frit milling cost and ink properties could therefore be found by including two frit sizes into an ink: a larger particle size frit, for example 1.5 to 2.0 or more micron particles, that provides most of the required properties, together with a smaller particle size frit of 0.3-0.8 microns that provides such property as gloss. A combination of frit sizes may even impart additional advantages. While an ink containing only one frit size will dry to form a pre-fired layer that contains small voids between the packed particles, the addition of a small amount of smaller particles will allow some of the voids to be filled, resulting in a denser dry layer and consequently an ink that can be fired more easily, at a lower time/temperature combination. The ratio of frits may be tuned to provide the desired mixture for a specific application. For example, a ratio of larger particle size frit to smaller particle size frit of approximately 10:1 supports the formation of a dense, fast firing ink layer, where a ratio of 2:1 supports a higher gloss and opacity fired ink layer.
Size and Selection of Pigment and Other Additive Particles
Maximal resistance to settling of particles, pigment and other additive particles could also be enhanced by milling them to a small size with the use of a controlled flocculation dispersant. For many pigments this is easily accomplished since they are easy milled to small sizes, or even sold as standard at small particle sizes. For example, titanium dioxide is typically supplied at a particle size of around 250 nm, since at this size its ability to scatter visible light is maximized.
A variety of pigments have been tested and probably more could be used with the current ink to provide the ink with a desired color. For example, Copper Chromite Black Spinel commercially available from Shepherd Color Company, Cincinnati Ohio 45246 USA under trade names BK 430 and BK 30C965; Cobalt-aluminate-blue-spinel commercially available from Fredcolors 08211 Barcelona, Spain under trade names Inorplast Blue DC-1500 or Blue 385 commercially available from Shepherd Color Company; Oxides of Nickel, Cobalt and Titanium commercially available from Shepherd Color Company under trade name Green 5 or Oxides of Nickel, Cobalt, Titanium, and Zinc commercially available from BASF Chemical Company Ludwigshafen Germany; nickel antimony titanium yellow rutile commercially available from Shepherd Color Company under trade names Yellow 10C112 and Yellow 10P110 or Nickel rutile pigments available from Heubach GmbH 38685 Langelsheim Germany under the trade name Heucodur Yellow G 9064; Titanium Dioxide available from a large number of vendors and other pigments.
It should be noted that some inks could use certain large particle size pigments or functional particles. For example, some pigments lose their color or intensity of the color at small particle sizes. Inks containing such particles may not be possible to formulate without settling, requiring a printer with constant agitation of the ink. However, the use of aspects of this disclosure can still be relevant to such inks, for example for the provision of gloss and/or opacity, or to reduce the rate of settling to more manageable levels.
Controlled Flocculation Dispersants
Inkjet inks require low viscosity, high filterability, and jettability through small apertures. As such, conventional wisdom dictates that particles should be as well separated as possible and any aggregation or flocculation should be inhibited. This is particularly true since aggregation is known to be a common cause of settling and loss of gloss in coatings.
The current disclosure employs the use of “controlled flocculation” dispersants such as a low molecular weight unsaturated acidic polycarboxylic acid polyester with a polysiloxane copolymer commercially available from BYK-Chemie GmbH 46483 Wesel Germany under the name BYK-220S; a low molecular weight unsaturated acidic polycarboxylic acid polyester, commercially available from BYK-Chemie GmbH under the name of BYKUMEN, a partial amide and alkylammonium salt of a low molecular weight unsaturated polycarboxylic, commercially available from BYK-Chemie GmbH under the name of LACTIMON; a low molecular weight unsaturated polycarboxylic acid polymer commercially available from BYK-Chemie GmbH under the name of BYK-P-104; and an alkyl ammonium salt of a polycarboxylic acid commercially available from BYK-Chemie GmbH under the name of ANTI-TERRA-203/4/5. These dispersants cause the formation of weak networks between suspended particles. When utilized together with small frit particle size, the use of these dispersants was found to result in very slowly settling inks that unexpectedly retain low viscosity at working shear rates, together with ink filterability and gloss in the final printed product.
In cases where the minimization of settling is not a major concern, the use of controlled flocculation dispersants could be substituted by use of traditional dispersants. The milling of frit to particle size 0.3-0.8 microns in “traditional” deflocculating dispersants (for example, a family of dispersants commercially available under the trade name of BYKJET, or other DISPERBYK family dispersants such as DISPERBYK 106, 110, 116, 145, 180, etc.) provides frit that could be used alone or in combination with other frit batches to e.g. increase gloss, pigment loading or opacity.
Anti-Sagging and Anti-Settling Additives
In the case of inks that have otherwise low viscosity, anti-sagging and/or anti-settling additives such as solution of a modified urea commercially available from BYK-Chemie GmbH under trade names BYK-410, BYK-415 and BYK-430, could be used to improve the resistance of an ink to pigment and frit settling at the expanse of a raised viscosity. Inorganic anti-settling additives could also be utilized. Such additives can also help to reduce bleed during printing, although they tend to increase viscosity so may only be used in limited quantities.
Minimization of Density Mismatch Between the Solvents and Glass Frit
With all other variables constant, the rate of settling in an ideal dispersion is proportional to the difference in density between the liquid and the suspended solid. In typical frits for ceramic inks, bismuth oxide glass is used as a primary additive to achieve suitable thermo-physical and chemical properties. An alternative option to use zinc oxide in place of bismuth is less preferred on account of the lower chemical resistance that inks based on it can achieve.
However, the density of bismuth oxide glass frit is in the range of 5.6 to 7.5 g/cc while the density of zinc oxide is 2.6 to 3.3 g/cc. Thus, glass frits based on the zinc additive result in a lower density and therefore they sediment significantly more slowly. In this disclosure, the inhibition of sedimentation is found to bring advantages to ceramic inks, and therefore the use of zinc-based frits becomes unexpectedly more preferred, having a previously unconsidered density advantage over bismuth-based frits.
In addition, the density mismatch between liquid and solid can be minimized by the choice of a high density solvent system. Inkjet inks are typically based on solvents such as glycol ethers (density 0.9-1.0 g/cc) or hydrocarbons (density 0.7-1.0 g/cc). High density solvents could be employed as part of the solvent system to improve the settling rate. Examples include sulfur-containing solvents (e.g. sulfolane, density 1.26); chlorinated solvents (e.g. pentachlorobenzene, density 1.8); carbonates such as propylene carbonate (density 1.21 g/cc), and other high density solvents such as dimethyl malonate (density 1.15 g/cc). Solutes may also be added to increase the liquid vehicle density. (Generally, low sedimentation rates were achieved for inks wherein the density of the glass frit based on the zinc additive related to the density of the solvent at least as 3.3 to 1.0 or event better as 2.6 to 1.0.)
Use of High Viscosity Vehicle
The rate of settling of particles in a suspension is largely proportional to the viscosity of the suspending vehicle. Since the viscosity of the ink as a whole depends not only on the viscosity of the vehicle but also on the interactions of the particles, it can be possible to engineer inks with unusually high vehicle viscosity, particularly by the use of solvents that may normally be overlooked. Most solvents used in the formulation of inkjet inks have viscosity in the range 0.5-5.0 cP, but inks may be jettable at up to 25 cP or even more.
The ceramic mixture (+/−)-2,2-dimethyl-4-hydroxymethyl-1,3-dioxolane commercially available from Rhodia 69457 Lion France under the trade name Augeo SL 191, has a viscosity of ˜11 cP. Ethylene glycol has a viscosity of ˜16 cP, and Dowanol TPM has a viscosity of ˜5.5 cP. These solvents can be used at up to 50 wt % in inks. Higher viscosity solvents such as propylene glycol (42 cP), cyclohexanol (41 cP), and diethylene glycol (36 cP), can be used at up to 20 wt %. Such use of high viscosity solvents, even in mixtures together with lower viscosity solvents, provides a high viscosity vehicle that impedes sedimentation. A suitable mixture including both a high viscosity solvent and a high density solvent may provide the most optimal vehicle.
Depending on the choice of frit and pigments, as well as other considerations such as printability, safety, and environmental concerns, solvent systems other than those mentioned above could also be used. For example, hydrocarbon/paraffin-based nonpolar solvents such as Isoparaffinic Hydrocarbon commercially available from Exxon Mobil Company Houston, Tex. 77079-1398 USA under the trade name Isopar M, may be utilized.
Gelation Upon Standing
Sedimentation may be completely avoided by the controlled gelation of an ink upon standing in the absence of agitation, particularly in the absence of syneresis, which is a process that reduces homogeneity. Therefore, ink that gels upon standing for extended periods while remaining fluid and of printable viscosity on the timescale of printing is desirable. Inks that are gelled with a very weak energy may be brought back to fluidity with minimal shaking, much less than is required to redisperse settled inks. The strategies of small particle size, controlled flocculation dispersants, and anti-sagging/anti-settling additives, are all conducive to the creation of inks that exhibit the desired behavior.
Ink Preparation Processes and Examples
Milling of Frit
A comparative example of a bismuth-borosilicate frit “JFC004” commercially available from Johnson Matthey Plc., London EC4A 4AB Great Britain was wet-milled by bead-milling at 65-70% concentration in Dipropylene Glycol Monomethyl ether (DPM) with 2% BYK-220S. Viscosity reduction and particle size reduction rate were both found to be more efficient with this controlled flocculation dispersant than with any tested non-flocculating dispersant. With other dispersants the particle size reduction rate slowed and the slurry thickened before an ultimate particle size of 0.8 microns was reached, but with this controlled flocculation dispersant, a particle size of 0.6 micron with median distribution of 50% was achieved. FIG. 1 demonstrates the relation between the milling time and particle size.
Decreased Settling Rate—Small Particle Size
Dispersions of “JFC004” bismuth-based frit in DPM were adjusted to a concentration of 50 wt % inorganic solids. A small sample in an about 20 mm diameter sample vial was examined over time, and the amount of settling of the suspended solid bulk was noted. The small particle size sample was found to settle much more slowly than the large particle size sample:
Sample
Particle size (D50)
Settling (3 days)
Settling (7 days)
42-125-02*
0.58 microns
1 mm
1.5 mm
42-125-04
0.85 microns
2 mm
4.5 mm
*Ink sample numbers are numbers given by the authors of the present disclosure in course of the ink development process
It should be noted that the very small initial apparent settling of ˜1 mm may be the result of a syneresis-like process rather than true sedimentation. A 30% reduction in particle size (from 0.85 to 0.58 microns) resulted in 3× improvement in settling rate. This improvement is considerably more than could be expected from the ideal theory of dispersions (which would predict only a 30% improvement).
Decreased Settling Rate—Zinc Based Glass Frit
Dispersions of zinc-based and bismuth-based frits at similar particle sizes were adjusted to a concentration of 50 wt % inorganic solids in DPM. A small sample in an about 20 mm diameter sample vial was examined over time, and the amount of settling of the suspended solid bulk was noted. The sedimentation of the zinc-based frit, even at larger frit particles size was found to be considerably slower, practically negligible, than the bismuth-based fit. The authors of the disclosure assume that this phenomenon is mainly brought about by the lower density of the zinc-based frit:
Settling
Settling
Sample
Basis
Particle size (D50)
(3 days)
(1 week)
42-113-04
Zinc
1.00 microns
2 mm
2.5 mm
42-125-04
Bismuth
0.85 microns
2 mm
4.5 mm
The zinc-based glass frit was milled in DPM over a long period of time, and samples were periodically taken. These samples were diluted to provide frit dispersions at a particle concentration of 50 wt %, and were left to stand for 3 days. After this time, the amount of settling was measured (in terms of the height of nominally particle-free solvent at the top of the mixture). FIG. 2 is a plot that demonstrates that a linear relationship found between particle size and amount of settling.
Extrapolation of the linear relationship unexpectedly finds that at a particle size of 0.6 microns or less, settling could be completely arrested.
It should be noted that a portion of the initial apparent settling may be the result of a syneresis process rather than true sedimentation (Syneresis is understood to be the extraction or expulsion of a liquid from a gel). The superiority of the zinc-based frit in settling resistance is even more marked than the data immediately suggests, since the zinc frit is milled to a larger particle size, which would be expected to settle more rapidly.
Decreased Settling Rate—Use of Controlled Flocculation Dispersants
Although several controlled flocculation dispersants were screened, some were found to be incompatible with the solvent used in the studies (DPM), and some were found to cause an unacceptably high viscosity. Studies therefore concentrated on the controlled flocculation dispersant BYK-220S, which was found to give by far the best viscosity reduction of the tested dispersants while also having good compatibility with DPM. The authors of the present disclosure do not exclude that other suitable controlled flocculation dispersants will be found.
The settling rate of zinc-based frit was measured with controlled flocculation dispersant BYK-220S compared to Disperbyk-145 (the best-performing non-flocculating dispersant found for the frit):
Sample
Dispersant
Settling (3 days)
Settling (7 days)
42-113-01
BYK-220S (2%)
1.5 mm
2 mm
42-113-04
Disperbyk-145 (2%)
2 mm
2.5 mm
Although the improvement is small, the settling rate is nonetheless decreased by the use of the controlled flocculation dispersant. It should be noted also that typical ceramic inkjet inks settle at a much faster rate, for example 7 mm in 3 days and 14 mm in 7 days.
In addition to the decreased settling rate observed with controlled flocculation pigments, an additional advantage is found. After sedimentation has occurred, the sediment formed under controlled flocculation is much more mobile and easily redispersed than the sediment formed with “traditional” non-flocculating dispersants.
Improved Opacity—Small Frit Particle Size
Analysis of frit milled to different sizes found that very small particle size frit gave an advantage of increased opacity. Frit dispersions were adjusted to 50 wt % inorganic solids, and drawn down to give 60 micron-thickness wet layers.
Sample
Particle size (D50)
Opacity
42-125-03
0.58 microns
84%
42-125-04
0.85 microns
76%
The sample created from frit with a 30% smaller particle size (0.58 microns vs 0.85 microns) resulted in more than 10% higher opacity. The authors of the present disclosure believe that the reason for this increase in opacity is the larger number and smaller size of the voids between packed particles in the dried ink layer. It is advantageous to use smaller frit particle size for the production of many inks, particularly those involving transparent pigments where opacity is required.
Improved Gloss and Opacity—White Ink Preparation
White inks were prepared using bismuth-based frit milled to different sizes, and otherwise identical formulations. Pigment loadings of 10.5 wt % and 14 wt % were used. The pigment used was titanium dioxide at 250 nm particle size. This pigment tends to product matte inks, particularly at higher pigment loadings. Samples of the inks were drawn down at 60 microns layer thickness, then these samples were dried and fired at 690 C to give a final enamel. Gloss and opacity were measured:
Ink Sample
Frit size
Pigment
Gloss
Opacity
45-34-1
0.58 microns
10.5 wt %
114
97%
45-33-2
0.85 microns
10.5 wt %
72
94%
For the samples containing 10.5% pigment, the smaller frit particle size resulted in ink with a much higher gloss and opacity than the larger particle size did. The reason for the improved opacity is not clear, but the difference found is sufficient to offer a noticeably superior ink.
Ink Sample
Frit size
Pigment
Gloss
45-34-02
0.58 microns
14 wt %
50
45-02-02
0.85 microns
14 wt %
20
For the samples containing 14% pigment, less gloss was found. All the same, the gloss achieved for the smaller frit particle size was 2.5 times higher than that obtained with the larger frit particle size.
These inks also exhibited light gelation after standing for 24 hours. This gelation was sufficient to prevent sedimentation indefinitely, but the ink reverted to a liquid state after light shaking.
Increased Pigment Loading and Decreased Frit Requirement—Black Ink Preparation
Black inks were prepared using bismuth-based frit milled to different sizes and small particle size pigment. The inks were prepared with a total particle content of 49 wt %, but different frit: pigment ratios. Samples of the inks were drawn down at 30 and 60 microns layer thickness, and then these samples were dried and fired at 690 C to give final enamel. For comparison purposes a commercially available ceramic inkjet ink with an identical pigment loading was tested as a reference point. Gloss and opacity were measured:
Ink Sample
Frit size
Pigment
Gloss (60 μm)
45-35-01
0.58 microns
11.2%
125
45-35-03
0.58 microns
21 wt %
118
45-36-02
0.85 microns
21 wt %
25
The 60 micron samples demonstrate the ability of the small particle size frit to produce enamel layers with high gloss, even at a very high pigment content. At a high pigment content, the larger frit particles do not provide any significant gloss, while the smaller frit particles still give very little reduction from the low pigment content ink. At 60 microns wet thickness, opacity is extremely high and was not measurable.
Gloss
Opacity
Ink Sample
Frit size
Pigment
(30μ)
(30 μm)
45-35-03
0.58
microns
21 wt %
91
99.5%
45-35-01
0.58
microns
11.2 wt %
124
98.3%
CASS-0001*
~0.9
microns
11.2 wt %
110
97.4%
*This ink is commercially available from Dip-Tech Ltd., 44536 Kefar Sava Israel
In the 30-micron drawdown samples, opacity was measurable though very high. By eye, some light could be seen passing through the samples with 11.2% pigment, but no light transmission was visible for the sample with 21% pigment. The small frit particle size inks gave higher opacity than the commercial reference ink, even at the same pigment content. At the higher pigment content, opacity was even higher, with only a very small loss of gloss. Clearly an ink based on the small particle size frit could provide comparable gloss and opacity to the commercial ink in a much lower layer thickness—or alternatively higher gloss and opacity at the same layer thickness.
Mixture of Pigment Sizes
The commercial black ceramic inkjet ink CASS-0001 (Available from Dip-Tech Ltd. Israel), which contains a frit in the range 0.8-2.0 microns, was modified by adding 3.5% of a bismuth borosilicate frit milled to 0.7 microns. The resulting ink contained a mixture of frit sizes, with the ratio of smaller to larger frits being in the range of 1:7-1:15. The modified ink and the original CASS-0001 ink were compared after firing in a roller furnace at 610 C and 620 C for 105 seconds. The ink with the mixture of frit sizes provided a stronger blackness as well as a gloss that was higher by 10 gloss units. | The current document discloses an inkjet ink that is characterized by exceptionally low sedimentation rate of glass frit and pigment particles. Practically, the ink reversibly gels upon extended standing, thus preventing sedimentation entirely. | 2 |
This is a continuation of application Ser. No. 179,325, filed Aug. 18, 1982, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to diesel engines and, more specifically, to ultrasonic fuel injectors.
2. Description of the Prior Art
Diesel engines designed according to the precombustion chamber system have the combustion chamber divided into a precombustion chamber, which is incorporated into the cylinder head, and a main combustion chamber which is positioned between the bottom edge of the cylinder head and the head or crown of the piston. The precombustion chamber into which the fuel is injected and in which combustion initially takes place, is connected to the main combustion chamber by means of a narrow slot or flow passage.
In operation, as the piston moves in the direction of the cylinder head air is forced into the precombustion chamber, and near the end of this compression stroke fuel is injected into the precombustion chamber. Subsequently, the combustion products are returned through the flow channel from the precombustion chamber into a secondary combustion chamber formed in the piston head. The combustion of this fuel-air combination generates the thrust necessary to produce the power stroke of the piston.
It should be noted that although U.S. Pat. No. 4,122,804 to Kingsbury et al describes a diesel engine designed in accordance with precombustor theory and having a precombustion chamber using a pencil-type fuel injector, Kingsbury et al does not teach a system for ultrasonically injecting fuel into the combustion chamber.
SUMMARY OF THE INVENTION
Accordingly, there is provided by the present invention a means of introducing ultrasonic vibrational energy into a diesel fuel injector. The injector comprises a body which houses a fuel inlet means, a check valve head oriented within the fuel inlet, and a means for inducing high-amplitude, high-frequency oscillations into the check valve head.
OBJECTS OF THE INVENTION
Therefore, it is an object of the present invention to incorporate an ultrasonic transducer into a check valve of a diesel injector.
Another object of the present invention is to provide an ultrasonic means for atomizing fuel.
Yet another object of the present invention is to provide a high-efficient diesel engine.
Another object of the present invention is to provide a diesel engine which burns fuel more completely.
Still another object of the present invention is to provide a diesel engine whose particulate matter output is significantly decreased.
Yet another object of the present invention is to provide a diesel engine which decreases the production of nitrogen oxides.
Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross-sectional view of an injector having a magnetostrictive-driven check valve head.
FIG. 2a is a schematic view of a poppet valve incorporated in the injector.
FIG. 2b is a schematic view of a pintle valve incorporated in the injector.
FIG. 3 is a schematic cross-sectional view of an injector having a piezoelectric-driven check valve.
The same elements or parts throughout the figures of the drawings are designated by the same reference characters, while equivalent elements bear a prime designation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to FIG. 1, there is shown a first ultrasonic diesel fuel injector 10. Injector 10 comprises injector body 12 which houses fuel inlet means 14, check valve generally designated at 15 and having check valve head 16, and means for inducing high-amplitude, high-frequency oscillations 18 into check valve head 16. Functional check valve heads include by the poppet-type, as shown in FIG. 2a, and the pintle-type shown in FIG. 2b.
In FIG. 1, means for inducing high-amplitude, high-frequency oscillations 18 comprises drive coil 20, check valve shaft 22 which comprises a magneto strictive material, and backing stub 23 which comprises a non-magnetostrictive material. As described in copending application U.S. Ser. No. 156,987 filed June 6, 1980, entitled Ultrasonic Diesel Fuel Injector, by Bruce W. Maynard, Jr. et al, included herein by reference, the check valve will, depending upon specific request, be driven at a frequency ranging from about 10 to about 10,000 kilocycles.
Turning now to FIG. 3, there is shown an injector 10' which differs from injector 10 only in the means for inducing high-amplitude, high-frequency oscillations 18' into check valve head 16'. In this embodiment, a piezoelectric element 24 is used to provide the high-frequency oscillations required to atomize the fuel instead of the magnetostrictive-driven poppet valve head 16.
Although many various operational modes will provide the desired atomization, the preferred operational sequence is as follows: Fuel flows through inlet means 14 causing check valve 15 to open against conventional biasing means 26. In the open position, FIGS. 2a and 2b, check valve head 16,16' is displaced from valve seat 28,28' by a gap 30,30', of about two-thousandths of an inch in size. Once check valve 15,15' is open, the means 18,18' for inducing the high-amplitude, high-frequency oscillations is activated. After a predetermined amount of fuel has been injected, means 18,18' can be turned off and valve 16,16' is closed.
Although the preferred operational mode described above teaches a specific sequential operation in conjunction with an on/off ultrasonic vibrational mode, it should be noted that neither the specific sequence described nor the specific on/off mode must be followed, since different situations could require different operational modes for the subject injectors, 10,10'.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | An ultrasonic diesel fuel injector comprises an injector body including a means for flowing fuel through the injector body, a check valve located within the means for flowing fuel, and a means for ultrasonically vibrating the check valve. | 5 |
BACKGROUND OF THE INVENTION
The invention relates generally to stock transporting conveyors and more particularly to roller conveyors utilized to receive and rotatingly transport cylindrical stock.
The transportation of objects on longitudinally translating conveyors is perhaps the most commonly utilized scheme for transporting material and partially fabricated products from work station to work station on a production line. Frequently, the conveyor will form a component of the work station in that the product will remain supported on the conveyor during a fabrication step. Furthermore, rotation may be imparted to the product as it translates along the conveyor by driving the conveyor rollers upon which the work rests in order to ensure uniform application of heat, material coatings, or for similar process steps. For example, a given forming operation may require that an article be uniformly heated prior to arriving at a given forming station. Rotating the article while it is translating past various gas or infrared heaters disposed along the conveyor assembly will conveniently achieve this goal. Co-owned U.S. Pat. No. 3,257,186 discloses such a device and function.
A similar approach may be utilized to permit rapid inspection of the entire circumference of a cylindrical container. In U.S. Pat. No. 3,901,381, vertically oriented ware translating on a horizontal conveyor is rotated at an inspection station by opposed, rapidly moving belts.
A forming operation which requires torque or rotational speed in excess of that which can be transferred to the rotating article simply by gravitational contact with the conveyor rollers may necessitate additional componentry. If simply additional torque is required, frictional contact between the rotating articles and the conveyor rollers may be improved by increasing the contact force. A stationary member disposed above the conveyor rollers which engages the upper portions of the articles may be utilized to do so. Naturally, if precautions are not taken, sliding contact between this member and the articles may deface or damage the outside surface thereof. In the second instance, if higher speeds are required, a moving wheel or belt may be utilized to engage the articles from above and rotate them at such a higher desired speed. In most instances, the conveyor rollers will be fabricated of steel or other durable material and damage from scoring or other abrasion will almost invariably result from the sliding of the article against the slower moving conveyor rollers as it rotates.
This specific situation exists in horizontal glass production and tooling lines. Elongate cylindrical glass articles are rotated and simultaneously translated along a roller conveyor past various heating and forming stations. Typically, at least one of these forming stations necessitates the rotation of the articles at a speed greater than that imparted to them by the rotating conveyor rollers. Such higher speed rotation is provided by a rotating wheel or belt disposed above the conveyor assembly at the desired location which serially engages the articles and rotates them at a speed faster than the speed imparted by the conveyor rollers. Generally speaking, the conveyor rollers, due to their exposure to relatively high temperatures, must be fabricated of a hard durable material, preferably metal. The higher speed rotation of the glass articles against the conveyor rollers invariably results in scoring and aesthetic degradation of the exterior surface of the articles.
SUMMARY OF THE INVENTION
The instant invention comprises a roller conveyor apparatus for receiving and transporting cylindrical articles as they are transported past work stations which necessitate the rotation of the cylindrical articles at a speed higher than the speed imparted to them by the rotation of the conveyor rollers. The conveyor rollers are disposed on spaced-apart parallel shafts. The shafts are supported for rotation in adjacent interconnected structures which translate along a conveyor supporting platform. Each of the rollers may be a solid cylinder or comprise plural, spaced-apart discs which engage the articles and includes a chain drive sprocket which engages a chain coextensively disposed on the conveyor supporting platform. As the conveyor rollers translate along the platform, the chain may be independently translated to maintain the rollers in a stationary position or rotate them at a selected speed. A one-way or overrunning clutch assembly is operably disposed between the chain sprocket and each conveyor roller or plurality of rollers disposed upon a common shaft. A drive member such as a wheel or belt is appropriately disposed above the conveyor assembly at a desired location, such as a tooling station, and engages the articles, rotating them at a speed higher than the speed imparted to them by the conveyor rollers. When urged to turn at a speed higher than the speed at which the chain is driving them, the overrunning clutches disposed between the rollers and the drive sprockets release and allow the conveyor rollers to free wheel at the speed of rotation dictated by the rotating stock or article, thus eliminating sliding contact between the conveyor rollers and the article and possible damage resulting therefrom.
Thus it is an object of the instant invention to provide a translating conveyor having rotating rollers driven through overrunning clutch devices.
It is a further object of the instant invention to provide a roller conveyor apparatus having both an overrunning conveyor roller drive for a rotating cylindrical object supported by the conveyor roller and auxiliary drive means for rotating such objects at a speed different from that speed imparted by the conveyor rollers.
It is a still further object of the instant invention to provide a roller conveyor apparatus having rollers which are driven at a first speed and which free wheel when overdriven at a second, faster speed thereby minimizing or eliminating scoring or other damage to the outside surface of the articles.
Still further objects and advantages of the instant invention will become apparent by reference to the following specification and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of an article conveyor according to the instant invention;
FIG. 2 is a fragmentary side elevational view of an article conveyor and work station incorporating the instant invention; and
FIG. 3 is a full sectional view of an article conveyor according to the instant invention taken along line 3--3 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a roller conveyor according to the instant invention is illustrated and generally designated by the reference numeral 10. The roller conveyor 10 includes a horizontally extending beam 12 which defines a smooth upper surface 14. The beam 12 also defines a longitudinally extending re-entrant channel 16. The channel 16 is preferably positioned such that it substantially equally divides the upper surface 14. The purpose of the channel 16 will be described subsequently. A longitudinally extending support rail 18 is disposed in parallel, coextensive relationship with the beam 12. The support rail 18 may be spaced from and secured to the beam 12 by suitable stand-offs or spacers 20 and appropriate fastening means such as threaded fasteners, weldments or other means not illustrated. The support rail 18 defines a smooth upper surface 22.
Referring now to FIGS. 1 and 3, the roller conveyor 10 also includes a plurality of longitudinally translating carriage blocks 30. The carriage blocks 30 are disposed for sliding translation along the upper surface 14 of the beam 12 and each includes a selectively removable fastener 32 which seats within a suitable opening 34 in the carriage block 30. The fastener 32 secures a longitudinally extending, flexible endless drive band 36 to the carriage block 30. The drive band 36 is a continuous member which translates along the beam 12 and transfers translational energy from a suitable drive means (not illustrated) to the carriage blocks 30. Various other linear drive configurations such as a chain drive are well known in the art and may be used in place of the drive band 36 illustrated.
Each of the carriage blocks 30 provides suitable mounting for anti-friction devices such as a pair of ball bearings 40. The ball bearings 40 in turn, provide rotational mounting for a transversely extending stub shaft 42. Secured to the stub shaft 42 by suitable means such as an interference fit or fasteners at respective locations adjacent the transverse ends of the carriage block 30 are a pair of equal diameter roller discs 44. The discs 44 each define circular peripheral surfaces 46. The selection and utilization of a pair of roller discs 44 or, alternatively, a single, elongate roller or a greater plurality of roller discs 44 on each stub shaft 42 will generally be dictated by the application of the roller conveyor 10. Thus it should be apparent that the configuration illustrated is exemplary and that the invention should be construed to include all functionally equivalent roller arrangements.
The stub shaft 42 defines a cylindrical surface 50 about which an overrunning or one-way clutch assembly 52 is concentrically disposed. The overrunning clutch assembly 52 may be a sprag or roller type and preferably extends axially along a significant portion of the cylindrical surface 50 in order to evenly distribute bending moments associated with the mechanical configuration. This may, of course, be achieved by the utilization of plural, narrow overrunning clutch mechanisms 54 as illustrated or, alternatively, a lesser number of wider mechanisms. In either event, the overrunning clutch assembly 52 is deemed to be well known in the art and due to this fact, will not be further described. The overrunning clutch assembly 52 is axially restrained upon the cylindrical surface 50 by means of a suitable retaining ring 58 or similar fastener disposed in a circumferential groove (not illustrated) in the cylindrical surface 50. The overrunning clutch assembly 52 is securely disposed within and provides mounting for a cylindrical drive housing 60. Disposed about the periphery of the drive housing 60 in vertical alignment with the support rail 18 are a plurality of chain receiving teeth which define a chain drive sprocket 62. An endless drive chain 64 supported upon the upper surface 22 of the support rail 18 engages the chain drive sprocket 62. The drive chain 64, in an arrangement similar to the drive band 36, extends longitudinally the full length of the beam 12 and engages a variable speed drive means (not illustrated) which circulates the drive chain 64 at a preselected speed.
Referring now to FIGS. 1 and 2, an auxiliary drive assembly 70 is disposed above the beam 12 and preferably includes a pair of pulleys 72. The pulleys 72 are disposed for rotation about stationary axes disposed above and parallel to the axes of rotation of the stub shafts 42 and transverse to the direction of translation of the carriage blocks 30. A drive means (not illustrated) provides rotational energy to at least one of the pulleys 72 which in turn causes circulation of a belt 74 disposed thereabout. Preferably, the pulleys 72 and drive belt 74 are disposed substantially medially between pairs of the roller discs 44 disposed on the stub shafts 42. The drive assembly 70 is positioned longitudinally along the roller conveyor 10 at a location where it is necessary to increase the rotational speed of cylindrical stock such as articles 78 supported between adjacent pairs of circular peripheral surfaces 46 on the roller discs 44 in order to facilitate a fabrication or finishing process. Thus, a mechanism 80 for tooling, forming, cutting, polishing, finishing, painting, or other fabrication or finishing step will also be positioned at the situs of the drive assembly 70. The fabricating mechanism 80 is schematically illustrated by the phantom line enclosure. A longitudinally extending backstop 82 is disposed generally above the support rail 18 and provides a fixed reference surface against which the articles 78 may abut.
The operation of the roller conveyor 10 according to the instant invention will now be described with reference to all of the drawing figures. As generally stated previously, the carriage blocks 30 translate along the upper surface 14 of the beam 12, past various forming, heating and other fabrication mechanisms, one of which is illustrated in FIG. 1 and designated by the reference numeral 80. Cylindrical stock such as glass tubing or other articles 78 are supported slightly above the nip of adjacent pairs of roller discs 44. As the carriage blocks 30 and thus the articles 78 translate along the beam 12, the drive chain 64 may be translated to cause rotation of the drive sprocket 62, the roller discs 44 and thus the articles 78 disposed therebetween. As a specific example, assume the drive band 36 is moving from right to left in FIG. 1 and that the drive chain 64 is moving in the opposite direction. The mounting blocks 30 will thus move from right to left and the roller discs 44 will rotate in a counter-clockwise direction, rotating the articles 78 supported thereby in a clockwise direction. In this mode of operation, the overrunning clutch assembly 52 is locked together to transfer power from the drive sprocket 62 to the cylindrical surface 50 of the stub shaft 42. The pulleys 72 rotate in a counter-clockwise direction and the surface speed of the belt 74 of the drive assembly 70 is greater than the rotating surface speed of the roller discs 44 and thus equally greater than the surface speed of the articles 78 supported by the roller discs 44. As the articles 78 translate into the region of the drive assembly 70 and mechanism 80, they are engaged by the belt 74 and are accelerated such that the surface speed of the articles 78 equals the surface speed of the belt 74. Frictional contact between the articles 78 and the roller discs 44 likewise causes the discs 44 and the stub shafts 42 to increase their speed of rotation correspondingly. At this time, the overrunning clutch assembly 52 releases and frees the stub shaft 42 and the roller discs 44 from the rotational drive provided by the drive chain 64. Thus the articles 78 are free to rotate at a speed dictated by the surface speed of the belt 74 in order to facilitate a given fabrication step by the mechanism 80. Since the roller discs 44 increase their rotational speed such that nonslipping contact is achieved with the articles 78, damage such as scoring of the articles 78 due to surface speed disparities between the articles 78 and the roller discs 44 is minimized or eliminated.
The foregoing disclosure is the best mode devised by the inventors for practicing this invention. It is apparent, however, that devices incorporating modifications and variations will be obvious to one skilled in the art of production conveyors. Inasmuch as the foregoing disclosure is intended to enable one skilled in the pertinent art to practice the instant invention, it should not be construed to be limited thereby but should be construed to include such aforementioned obvious variations and be limited only by the spirit and scope of the following claims. | A conveyor apparatus for receiving and transporting cylindrical stock or articles past work stations includes a plurality of rollers disposed along spaced-apart parallel axes. The rollers are driven through one-way or overrunning clutches and rotate cylindrical stock disposed between adjacent pairs of rollers. At a work station, a moving member such as a belt engages the stock and rotates it at a speed higher than the speed imparted to it by the rollers. The overrunning clutches release the conveyor rollers and rotate with the stock at a correspondingly higher speed. The constant, non-slipping contact between the rollers and stock minimizes such difficulties as scoring of the stock and significantly improves product quality and appearance. | 1 |
FIELD OF THE INVENTION
The field of the invention is load management systems. More particularly, the field of the invention is load management systems for a power network which utilize remote load data.
BACKGROUND OF THE INVENTION
The power systems of electrical power companies regularly encounter periods of peak load demand. During these periods the power drain placed upon the power system is significantly higher than average. It is excessively costly to maintain the supply of power during peak load periods. Electrical power production is most inefficient during these periods. Moreover, there is added cost in the construction of power generating facilities as they must be built to accommodate maximum power consumption. Failure to meet peak demands can result in power failure or blackout.
Significant overall savings can be obtained where peak power demands are reduced and spread out over a period of time. To achieve this result, load management systems monitor the power supply and demand and selectively turn off deferrable loads, such as water heaters and air conditioners, during peak load periods to evenly distribute the power demand over time. In a typical load management system, remote load controllers are addressed by omnidirectional radio transmissions from a central unit. Transmissions are received and decoded by the remote controller units which selectively control the functions of particular loads in response to the commands transmitted by the central unit. Power consumption is monitored at various points in the power network and the load data acquired is relayed to the central control unit via telephone lines. Such systems in the prior art are limited in their capacity to efficiently cover some power networks where the central control unit is not centrally located or where the network has an elongated configuration and by the availability and high cost of phone lines in remote regions.
SUMMARY OF THE INVENTION
In general terms, the present invention relates to a power management system for a power network which both addresses remote load controllers and acquires load data through a directional retransmission network. In one embodiment, a central controller processes power load data and generates digital messages which address loads and command the selective connection and disconnection of loads. The central controller transmits the generated digital messages via radio frequency transmissions. Programmable retransmission stations receive, decode, and directionally retransmit the digital messages. Addressable remote load controllers receive and decode transmitted digital messages and operate to connect and disconnect loads in response to command messages received by the addressed load controllers. In response to other digital messages, addressable data acquisition units sense loads at points in the power network and operate to generate digital load data messages. Retransmission stations receive load data messages from the addressable data acquisition units, retransmit load data messages through the retransmission network to the central controller. Yet other digital messages are translated into paging signals and disseminated to remote paging units.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of a load management system for a power network. Specific addressable, remotely controllable loads have not been shown in FIG. 1.
FIG. 2 is a diagram of a portion of the load management system and power network of FIG. 1, additionally illustrating the connection of addressable, remotely controllable loads to the power network and the selective preprogramming of the retransmission stations.
FIG. 3 is a diagram of a central controller of FIGS. 1 and 2.
FIG. 4 is a diagram of a retransmission station of FIGS. 1 and 2.
FIG. 5 is a diagram of a load data acquisition monitor of FIGS. 1 and 2.
FIG. 6 is a diagram of an addressable, remotely controllable load of FIG. 3.
FIGS. 7A and 7B illustrate the transmission format for control and data words used by the retransmission network of FIGS. 1-6.
FIG. 8A more specifically shows the format of the first control data word (path) in the transmission format of FIG. 7A.
FIG. 8B more specifically shows the format of the second control data word (directing and identification) in the transmission format of FIG. 7A.
FIG. 8C more specifically shows the format of the third control data word (track and reach) in the transmission format of FIG. 7A.
FIG. 8D more specifically shows the format of the fourth control data word (activation) in the transmission format of FIG. 7B.
FIG. 8E more specifically shows the format of the last control data word (end signal) in the transmission format of FIG. 7B.
FIG. 9 illustrates the manner in which digital encoder/decoder processes digital messages transmitted in the retransmission network.
FIG. 10 a diagram of a remote paging unit of FIGS. 1 and 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
Referring now to the drawings, FIG. 1 shows an electrical power network and load management system embodying the present invention. The power network includes power generating source 115, power distribution lines 116, and power loads (not shown). Power distribution lines 116 carry electrical power supplied by power generating source 115 to the power loads. The power loads are selectively connectable to the power network to draw electrical power from power generating source 115. At least some of the power loads are addressable and remotely controllable loads. These remotely controllable loads include deferrable loads which are remotely controlled by central controller 200 to more evenly distribute the power demand during peak load periods.
Central controller 200 both controls the remotely controllable loads and accesses power load data via a network of directional retransmission stations R1-R12. Retransmission stations R1-R12 (1) receive and retransmit load command, load data access command, and paging information through the retransmission network to the point of dissemination, (2) disseminate load command information to target controllable loads, (3) disseminate load data access commands to target load monitors M1-M14, (4) receive and retransmit load data to central controller 200, and (5) disseminate paging transmissions to remote paging units P1-P8.
FIG. 2 shows a portion of the power network and load management system of FIG. 1, additionally showing the connection of addressable, remotely controllable loads 11-69 and the selected coding of retransmission stations R1-R6. The specific dip switch settings for retransmission stations R1-R6 determine their relation in the retransmission network, as will be more fully described.
Referring now to FIG. 3, central controller 200 includes computer processor 221, radio transmitter 222, and radio receiver 223. Computer processor 221 processes power network supply and load data and generates digital messages. The digital messages generated by computer processor 221 (1) address loads in the power system to command the connection and disconnection of addressed loads to and from the power generating source, (2) address load monitors for load data acquisition, and (3) address remote paging units. Radio transmitter 222 transmits the digital messages generated by processor 221 into the retransmission network. Radio receiver 223 receives radio frequency messages from the retransmission network and relays received messages to processor 221. The received messages include load data messages generated by remote load monitors in response to previously generated load data acquisition messages. The particular specifications of transmitter 222 and receiver 223 are a matter of personal preference, are well within the skill of the art, are not a part of the present invention, and will therefore not be described in further detail. Similarly, the specific operation of control by processor 221, i.e. the decision making process as to the connection and disconnection of the remote loads, the accessing of the remote load monitors, and the paging of the remote pages, do not form a part of the present invention. However, the formatting of the messages generated and received by processor 221 and the functioning of these messages within the retransmission network will be described in specific detail as they relate to the invention being claimed.
FIG. 4 is a diagram of retransmission station R1 as an example of one of the retransmission stations in the retransmission network. Receiver/transmitter 331 receives and transmits radio signals via directional antennas A1, A2, A3, and A4. Received signals are relayed to digital decoder/encoder 333 (line 332). Digital decoder/encoder 333 includes means for decoding received radio signals into digital messages and for processing the decoded messages. Digital decoder/encoder 333 also includes means for controlling the connection of specific directional antennas A1, A2, A3, and A4 to receiver/transmitter 331 via antenna switch control 334, which in turn operates to open and close antenna relay 335 (lines 336, 337, and 338). As will be more fully described later, digital decoder/encoder 333 is selectively pre-coded by dip switch packages 341, 342, 343, and 344 for desired field operation in the retransmission network. After processing digital messages received, digital decoder/encoder 333 encodes digital messages into audio for transmission by receiver/transmitter 331.
FIG. 5 is a diagram of power load monitor M6 as an example of one of the remote load monitors in the retransmission network. Radio messages received by transceiver 441 (through antenna 442) are relayed to data acquisition module 444 (line 443). Data acquisition module 444 monitors the load on power network at point 6. Data acquisition monitor 444 decodes received messages into digital format (box 451). Received digital messages are compared (box 452) to a pre-programmed address (dip switch package 453). Upon receipt of the appropriately addressed transmission, digital controller 454 accesses analog to digital converter 455 which generates a digital number corresponding to the load sensed at point 6 by load sensor 456. The sensed load data is converted into audio (box 457) and conveyed to transceiver 441 (line 446) for radio transmission. The preferred source code for data acquisition module 444 has been submitted as Exhibit A.
FIG. 6 is a diagram of addressable, remotely controllable load circuit 61, as an example of one of the remotely controllable load circuits in the retransmission network. Load L61 is connected to power generating source 115 through relay 562 and power line 116. Load controller 561 receives radio transmissions through receiver 563, and decodes the received transmissions into digital data (box 564). Received digital messages are compared (box 565) to a pre-programmed address (dip switch package 566). Digital controller 567 selectively connects and disconnects load L61 to and from power generating source 115 by closing and opening relay 562 in response to appropriate received and addressed messages.
As mentioned above, load controllers for loads 11-69 in the power network each has an address identifier (i.e. dip switch package 566) which need not be distinct, and responds to command messages when it receives and decodes the address identifier of that load controller. Load control data words are divided into two groups, zone identifier words, and command/address words. Zone code and command/address formatting is performed in the manner described in U.S. Pat. No. 4,352,992 to Buennagel and Koch, issued on Oct. 5, 1982, which is hereby incorporated by reference. Addressing of the power load monitors M1-M14 is formatted in the same manner.
Retransmission stations R1-12 receive operating instructions and addressing information from a group a five control words (FIGS. 8A-8E) that are transmitted as a part of a load control data group (FIGS. 7A and 7B). Each word consists of ten bits of data. The data is generated by a sequence of tone bursts. The first burst is always one of two tone frequencies (initial tone pair). The next nine tone bursts alternate between nonharmonic tone pairs. Regarding transmission formatting and signal reception, reference is hereby made to U.S. Pat. No. 4,352,992 to Buennagel and Koch, issued on Oct. 5, 1982, which has been incorporated herein.
FIG. 9 illustrates the above described operation of digital decoder/encoder 333 of FIG. 4 as it processes received messages (line 332). The preferred source code for digital decoder/encoder 333 is attached hereto as Exhibit B. Retransmission stations in the retransmission network directionally retransmit load management messages (i.e. data words in FIGS. 7A-B) within the retransmission network. The load management messages include (1)load control messages, (2) data acquisition command messages, (3) load data messages, and (4) paging signals. These load management messages are "carried" though the retransmission network by retransmission network messages which contain the group of 5 control words mentioned above and illustrated in FIGS. 8A-E. When appropriately signalled, a retransmission station disseminates the "carried" load management messages to the target load controllers, power load monitors, and/or remote paging units.
The first control word to be received by retransmission stations is a path address word (FIG. 8A). A data word is identified as a path address word by having the binary number 100 in its first three bits (box 101). Retransmission stations require that the first word that it decodes be a path address word. If the first word decoded is not a path address word, it will be ignored. If the first word decoded is a path address word, the contents of the path bits are compared (box 102)to the path address for that particular retransmission station (dip switch package 341). If the path address received does not match the stored path address, then further decoding is discontinued until a new path address word is received. If the address matches the data stored in the dip switch package 341, then decoding continues.
The second control word (direction and path/station identifier--see FIG. 8B) is identified by a binary 101 in its first three bits. Retransmission stations require the second word decoded to be a direction and path/station identifier word (box 103). If the second word decoded is not a direction and path/station identifier word, the retransmission station will abort the sequence and discontinue further decoding until a new path address word is received. If the second word decoded is a direction and path/station identifier word, the contents of the path/station identifier bits are compared (box 104) to the path/station identifier address coded into the receiving retransmission station (dip switch package 342). If the identifier addresses do not match, further decoding is discontinued until a new path address word is received. If the addresses do match, decoding continues.
The third control word is a track and reach control word (FIG. 8C). The track and reach control word is identified by a binary 110 in its first three bits. The following data bits include track selection bits and reach bits. A receiving retransmission station requires that the third word decoded be identified as a track and reach word (box 105). If the third word decoded is not a track and reach word, further decoding is discontinued until a new path word is received. If the third word decoded is a track and reach word, the receiving retransmission station compares (box 106) the track select bits with the preprogrammed track switches of the receiving retransmission unit (dip switch package 343). If the receiving retransmission station is not a member of the track selected by the third control word, then the sequence is aborted. Otherwise, decoding continues. A comparison is also made between the reach bits of the third control word and the path/station identifier address coded into the receiving retransmission station (dip switch package 342). The reach signal indicates how far out into the retransmission network a message is to be carried. If the signalled reach is less than the path/station identifier address of the receiving retransmission station, there is no need for further processing, and the sequence is aborted.
The fourth control word (activation signals--see FIG. 8D) is identified by a 111 as its first three bits (box 107). The remaining bits identify which retransmission stations in the chain are to be used to disperse the load control data and which retransmission stations are to forward load control data to other retransmission stations (box 108). Bits 4 through 10 correspond to identification addresses 1 through 7 respectively (dip switch package 342). A one in an activation bit signifies that the corresponding retransmission station with the corresponding identification address (dip switch package 342) is to disperse the load control data to the addressable, remotely controlled loads in its region. The directions of such transmissions is controlled by the data transmitted in the direction select portion of the second control word (FIG. 8B), with a binary one in any of the bit locations signifying that the directional antenna corresponding to that bit location to be activated for retransmission (box 109). The carried load management messages are then disseminated (box 119). That is, they are encoded into audio (box 120) and sent to receiver/transmitter 331 for dissemination to the targeted load controllers, and/or power load monitors (line 339).
A zero in the activation bit location corresponding to the identification address signifies that the retransmission station is merely to retransmit the received message to the next station in the chain. In this event, a one is added to the path/station identifier portion of the second control word so that the next retransmission station in the chain can properly identify its signal box (110).
Data acquisition is performed in the following manner: A binary 0000 in the direction select portion of the second control word (box 113) and a 1 in test bit of the third control word (box 115) signify that data acquisition is to be performed. When a data acquisition request is made, the retransmission station which is to actually perform the data acquisition is the last station in the chain, thus a comparison of the reach portion of the third control word (FIG. 8C) and the identification address portion of the second control word (FIG. 8B) reveals whether the receiving station is to perform the data acquisition or merely to retransmit the request along the chain (114). Multiple load data acquisition monitors can be accessed by a single retransmission station. Access is determined by activation control word (FIG. 8D) with the activation bits signifying which of a selected number of load data acquisition monitors are to be polled (box 116).
When data acquisition is being performed, the data generated by the accessed load monitor is carried via the retransmission network back to central controller. In this event, return network 121 is enabled which maintains the connection of the activated antenna for reception of the returning signal. Upon receipt of the returning transmission, the initializing antenna is connected (i.e. the antenna which is connected to monitor transmissions emanating from central controller 200), and the returning message is retransmitted back toward central controller. This function is repeatedly performed by each station in the track until the returning signal is ultimately received by central controller 200. It is to be noted that although the return network has been described only in terms of data acquisition, it may also be used to verify load command and paging dissmination. The verification bit of control word 1 shown in FIG. 8A is available for this purpose.
In addition to carrying load control and data acquisition messages, the retransmission network operates to page remote paging units. A binary 0000 in the direction select portion of the second control word (box 113) and a 0 in test bit of the third control word (box 115) signify that paging is to be performed by the last retransmission station in the transmission chain. As with the data acquisition mode, a retransmission station determines its function in the chain by a comparison between the path/station identifier portion of the second control word and the reach portion of the third control word (box 114). Where dispersion is indicated, the data words are retransmitted as a two tone sequential frequency transmission, which is the commonly used format for a paging signal (box 117).
The reception of the fifth and final control word (FIG.8E) signifies that a complete retransmission network message has been received box (122).
FIG. 10 is a diagram of remote paging unit P6 as an example of one of the remote paging units in the retransmission network. Receiver 661 receives radio transmissions through antenna 662. Paging sequence logic 663 compares received transmissions to a pre-programmed address in a two tone sequential format, accessing 1st tone filter 664, and when it is appropriately received, further accessing 2 and tone filter 665. Paging sequence logic then activates audio beeper 666 when paging unit P6 has been appropriately addressed.
The operation of individual components within the system having been heretofor described, examples of the system operation in the control of selected remote loads, in the accessing of load data, and in the paging remote paging units, will now be given.
Say that addressably controllable load 21 is to be disconnected from power generating source 115. Central controller 200 generates a retransmission network message carrying a load management message which addresses and commands the disconnection of load 21. The retransmission network message signals itself to be carried along path 1 (control word 1) to path/station 1 (word 2), along track 1 (word 3). The network message is to reach path/station 2 (word 3) and path/station 2 is to be activated (word 4) to disseminate the carried load management message in direction 3 (word 2).
The generated message is received and processed by retransmission station R1. No other unit will act in response to the initial generated message as no other unit has been pre-coded with all the identifying data of that message. Upon processing of the network message, retransmission station R1 (1) ascertains that it is not to be activated for dissemination, (2) adds one to the path/station identifier to signify that the second station in path 1, track 1 is to receives its retransmitted message, (3) connects its first antenna (dip 344) as the direction in which the message is to be sent, and (4) retransmits the retransmission message.
This retransmission is received by retransmission station R2. Upon processing of the retransmitted message, retransmission station R2 (1) ascertains that it is to be activated for dissemination, (2) connects the third directional antenna as indicated by the received message, and (3) disseminates the load management message which was carried by the retransmission network message. This transmission is received by remote load controller 21, which detects its address and responds to the command by disconnecting its load.
Say that power load data is to be accessed from load monitor M6. Central controller 200 generates a retransmission network message carrying a load management message which addresses load monitor M6. The retransmission network message signals itself to be carried along path 2 (control word 1) to path/station 1 (word 2), along track 1 (word 3). The network message is to reach path/station 1 (word 3) and path/station 1 which is to disseminate the data acquisition request to load monitor M6 (word 4).
The generated message is received and processed by retransmission station R6. Upon processing of the network message, retransmission station R6 (1) ascertains that it is to be activated for dissemination and data access, (2) connects the antenna for accessing monitor M6, (3) disseminates the load management message which was carried by the retransmission network message. This transmission is received by monitor M6, which detects its address and responds by transmitting a load data message. This load data message is received by station R6 which retransmits the load data back to central controller 200.
Lastly, say that remote paging unit P3 is to be paged. Central controller 200 generates a retransmission network message carrying a load management message which addresses paging unit P3. The retransmission network message signals itself to be carried along path 1 (control word 1) to path/station 2 (word 2), along track 2 (word 3). The network message is to reach path/station 2 (word 3) which is to disseminate the page to paging unit P3 (word 4).
The generated message is received and processed by retransmission station R1. Upon processing of the network message, retransmission station R1 (1) ascertains that it is not to be activated for dissemination, (2) adds one to the path/station identifier to signify that the second station in path 1, track 2 is to receive its retransmitted message, (3) connects its second antenna (dip 344) as the direction in which the message is to be sent, and (4) retransmits the retransmission message.
This retransmission is received by retransmission station R4. Upon processing of the retransmitted message, retransmission station R4 (1) ascertains that it is to be activated for dissemination of a paging signal, and (2) generates and disseminates a two tone sequential signal which addresses paging unit P3. This transmission is received by paging unit P3, which detects its address and responds by sounding a paging signal.
While there have been described above the principles of this invention in connection with specific apparatus and techniques, it is to be clearly understood that this description is made only by way of an example and not as a limitation to the scope of the invention. | A load management system for a power network which both addresses remote load controllers and acquires load data through a retransmission network. A central controller processes power load a data and generates digital messages which address loads and command the selective connection and disconnection of loads. The central controller transmits the generated digital messages via radio frequency transmissions. Programmable retransmission stations receive, decode and directionally retransmit the digital messages. Addressable remote load controllers receive and decode transmitted digital messages and operate to connect and disconnect loads in response to command messages received by the addressed load controllers. Addressable data acquisition units sense loads at points in the power network and operate to generate digital load data messages. Retransmission stations receive load data messages from the addressable data acquisition units and retransmit load data messages through the retransmission network to the central controller. Yet other digital messages are translated into paging signals and disseminated to remote paging units. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is one of the nine related co-pending U.S. patent applications listed below. All listed applications have the same assignees. The disclosure of each of the listed applications is incorporated by reference into all the other listed applications.
[0000]
Attorney Docket No.
Title
Inventors
US27626
STYLUS
Wang et al.
US29632
STYLUS
Liang et al.
US30242
TOUCH STYLUS
Shi-Xu Liang
US30383
TOUCH STYLUS FOR
Shi-Xu Liang
ELECTRONIC DEVICE
US30930
STYLUS
Liang et al.
US31159
STYLUS
Shi-Xu Liang
US31366
STYLUS
Shi-Xu Liang
US32040
STYLUS
Shi-Xu Liang
US32043
STYLUS
Shi-Xu Liang
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates to styluses, and particularly, to a stylus used with portable electronic devices.
[0004] 2. Description of the Related Art
[0005] With the development of wireless communication and information processing technologies, portable electronic devices, such as mobile phones and personal digital assistants (PDAs), are now in widespread use.
[0006] Styluses are usually provided and are secured within the outside wall of the portable electronic device for inputting information. The stylus need to be small or thin for a compact requirement of the portable electronic device. However, they may be uncomfortable to use.
[0007] Therefore, there is room for improvement within the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Many aspects of the present stylus and the portable electronic device using the same can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present stylus and a portable electronic device using the same. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0009] FIG. 1 is an isometric view of an exemplary stylus according to an embodiment.
[0010] FIG. 2 is an enlarged view of a sliding rod of the stylus shown in FIG. 1 .
[0011] FIG. 3 is an assembled view of the stylus shown in FIG. 1 .
[0012] FIG. 4 is a cross sectional view of the assembled stylus shown in FIG. 3 .
[0013] FIG. 5 is another assembled view of the stylus shown in FIG. 1 , the main body partially exposed to the outside.
[0014] FIG. 6 is a cross sectional view of the assembled stylus shown in FIG. 5 .
[0015] FIG. 7 is another assembled view of the stylus shown in FIG. 1 , the main body completely exposed to the outside.
DETAILED DESCRIPTION
[0016] FIG. 1 shows an exemplary stylus 100 used in a portable electronic device such as a mobile phone, or a personal digital assistant (PDA), including a main barrel 10 , a sliding rod 20 , a main body 30 and a stylus cover 40 . The sliding rod 20 and the main body 30 are assembled within the main barrel 10 . The stylus cover 40 is mounted to the end of the main barrel 10 .
[0017] The main barrel 10 is generally hollow defining an accommodating cavity 11 . The accommodating cavity 11 is enclosed by sidewalls 111 . The main barrel 10 further includes two opposite latching holes 13 and a securing pin 15 . The two latching holes 13 are defined through and aligned substantially perpendicularly to two parallel sidewalls 111 . The securing pin 15 can engage through and secure into the latching hole 13 . When the latching hole 13 secures the securing pin 15 , the opposite ends of the securing pin 15 are coplanar (flush) with the corresponding exterior surfaces of the sidewalls 111 , respectively.
[0018] FIG. 2 shows the sliding rod 20 having substantially the length with the main barrel 10 , and accordingly can be accommodated completely inside the main barrel 10 . The sliding rod 20 includes a rod base 21 and a rod body 23 . The rod base 21 has substantially the same shape and size with the accommodating cavity 11 to be slidably received in the accommodating cavity 11 . The rod body 23 protrudes substantially perpendicularly from the surface of the rod base 21 . The rod body 23 includes an exterior wall 231 , a securing holes 233 and a sliding groove 237 . The securing holes 233 have substantially the same shape and size as the latching hole 13 , and are defined through the exterior wall 231 adjacent to the rod base 21 . The securing holes 233 secures the securing pin 15 therein for securing the sliding rod 20 with the main barrel 10 .
[0019] The exterior wall 231 further defines a through longitudinal sliding groove 237 . The sliding groove 237 includes a sliding section 2371 , two opposite limiting sections 2373 and two opposite securing sections 2375 . The sliding section 2371 is located between and communicates with the two limiting sections 2373 . The securing sections 2375 are positioned at opposite ends of the sliding groove 237 and communicate with the limiting sections 2373 respectively. Each limiting section 2373 is located between and narrower than the sliding section 2371 and the securing section 2375 .
[0020] FIG. 1 shows the hollow main body 30 including a hollow body section 31 and a head section 33 connecting the hollow body section 31 . The body section 31 has substantially the same shape and size as the accommodating cavity 11 . The body section 31 includes a receiving space 311 , two positioning holes 313 and a positioning pin 315 . The body section 31 can receive rod body 23 therein. The two positioning holes 313 are defined through the body section 31 in communication with the receiving space 311 for latching the positioning pin 315 therein. The positioning pin 315 can be secured in the securing sections 2375 and the positioning holes 313 to secure the main body 30 with the sliding rod 20 . The head section 33 is opposite to the positioning holes 313 and defines a wedge-shaped latching slit 331 on the periphery of the main body 30 .
[0021] FIGS. 1 and 4 show the hollow stylus cover 40 having an end connected with a string 41 , and an opposite end integrally formed with e.g. two opposite latching portions 43 on the interior wall. The string 41 can be threaded into a connecting hole in an outside portion of the portable electronic device, enabling the securing of the stylus 100 with the portable electronic device. The latching portions 43 can latch in the latching slit 331 . Each latching portion 43 has a wedge-shaped section and includes a limiting wall 431 and an opposite resisting wall 433 . The limiting wall 431 is generally perpendicular with the interior wall of the stylus cover 10 , and the resisting wall 433 is inclined relative to the interior wall of the stylus cover 10 .
[0022] FIGS. 3 and 4 show an assembly of the stylus 100 . The rod body 23 is placed into the receiving space 311 with the positioning holes 313 aligning with the securing sections 2375 . The positioning holes 313 and the securing sections 2375 secures the positioning pin 315 . At this time, the main body 30 is slidably mounted on the sliding rod 20 . The assembled unit of the main body 30 and the sliding rod 20 is placed into the accommodating cavity 11 with the rod base 21 near the latching hole 13 and the securing holes 233 aligned with the latching hole 13 . The securing holes 233 and the latching hole 13 latch the securing pin 15 therein, and accordingly the main barrel 10 latches with the sliding rod 20 and the main body 30 . The latching slit 331 latches the latching portions 43 therein with the limiting walls 431 and the resisting walls 433 resisting against the interior wall of the latching slit 331 , latching the stylus cover 40 with the head section 33 accordingly, the assembly of the stylus 100 is completed.
[0023] FIGS. 4 through 7 show a process of changing the stylus 100 from a closed position to an open position. The stylus cover 40 is pulled away from the main barrel 10 . Due to the fixing of the sliding rod 20 with the main barrel 10 and the latching of the latching portions 43 into the latching slit 331 , the head section 33 and the body section 31 move relative to the sliding rod 20 and the main barrel 10 . In this process, the positioning pin 315 passes one of the limiting section 2373 into the sliding section 2371 , slides along the sliding section 2371 and passes the other limiting section 2373 to latch into the securing sections 2375 distal to the rod base 21 . At this time, the body section 31 is exposed completely out of the main barrel 10 . The stylus cover 40 can be further pulled to release the latching of the latching portions 43 and the latching slit 331 and accordingly removed away from the main body 30 . When the head section 33 is exposed the stylus 100 is ready for use.
[0024] It is to be understood that even though numerous characteristics and advantages of the present embodiments have been set forth in the foregoing description, together with details of assemblies and functions of various embodiments, 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 present invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | A stylus is disclosed including a main barrel, a main body receiving the main barrel, a stylus cover covering the main body, and a sliding rod assembled to the main barrel. The main body is slidably assembled to the sliding rod to transfer between being latched inside the main barrel and being exposed out of the main barrel. | 6 |
TECHNICAL FIELD
The present invention relates to an apparatus and a method for controlling a volume in digital telephones such as second generation mobile telephone terminals, third generation IMT 2000 image mobile telephone terminals, and ISDN (integrated service digital network) terminals. In particular, an apparatus and a method in accordance with an embodiment of the present invention measure background noise and adjust volume of received sound and/or ring signal accordingly.
BACKGROUND OF THE INVENTION
As telephones are popularized, they are used in various environments. Especially, as mobile telecommunication technology progresses, more and more people use mobile phones and telephone calls are made at any place at any time. However, large ring signal and loud voice for telephone sometimes bother people around the telephone user.
In such cases, usually telephone users increases voice tone or pitch because of small received sound, and the users forgets volume control of the ring signal because it is hard to adjust telephone ring signal rather than because they are rude. Therefore, if there are devices that are able to adjust telephone ring signal and volume of received sound automatically in response to various environments, the cases of inconvenience stated above will be definitely decreased.
Regarding this matter, Korea Patent Application No. 1991-025518 disclosed a technology adjusting volume of received sound automatically. The invention relates to an automatic level adjustment apparatus, which adjusts volume of received sound automatically in response to volume of transmitted sound. In this invention, since background noise doesn't perform any important role to adjust volume of received sound, volume of received sound may be varied on the basis of habit of telephone users.
Korea Patent Application No. 1995-035336 disclosed a telephone that adjusts volume of received sound automatically in response to background noise. The telephone is equipped with a microphone for collecting background noise and the collected background noise is utilized for adjusting volume of received sound automatically. Since the telephone measures background noise without discriminating between voice and non-voice, sometimes voice of telephone users are treated as noise, which may cause serious problem.
In addition, since additional circuitry is necessary to add such features to conventional digital telephones, the previous technologies causes cost increase and large sized telephones. Consequently, the previous technologies are not appropriate for state of the art digital telephones that pursue low cost, low power consumption, and low weight.
SUMMARY OF THE INVENTION
An apparatus and a method for volume control in digital telephone are provided. The digital telephone includes ring signal source, ring signal speaker, DSP (digital signal processor), and ADC (analog-digital converter). The ring signal source stores various sounds at transceiver and terminal. The ring signal speaker transmits ring signal provided by the ring signal source at in detecting ring signal. The DSP (digital signal processor) encodes and decodes input signal with voice codec. The ADC (analog-digital converter) converts analog signal into digital signal. The analog signal is provided from microphone of transceiver.
An apparatus and a method for volume control in digital telephone in accordance with an embodiment of the present invention includes background noise input part, input signal amplitude measurement part, and volume adjustment part. The background noise input part collects background noise and converts the noise into digital signals. The input signal amplitude measurement part measures amplitude of the background noise. The volume adjustment part adjusts ring signal amplitude provided from ring signal source in accordance with the amplitude of the background noise and generates the adjusted ring signal to ring signal speaker.
Preferably, the background noise input part includes a microphone of conventional transceiver and an ADC.
Preferably, the volume adjustment part compares sound pressure level of the measured background noise with unique minimum/maximum sound pressure of a digital telephone, adjusts ring signal volume on the basis of the minimum sound pressure if sound pressure level of the measured background noise is lower than unique minimum sound pressure of a digital telephone, adjusts ring signal volume on the basis of the maximum sound pressure if sound pressure level of the measured background noise is bigger than unique maximum sound pressure of a digital telephone, adjusts ring signal volume in proportion to the measured sound pressure level of the measured background noise if sound pressure level of the measured background noise is between the unique minimum sound pressure and the unique maximum sound pressure of a digital telephone.
An apparatus for volume control in digital telephone is provided. The digital telephone includes ring signal source, ring signal speaker, DSP (digital signal processor), ADC (analog-digital converter), and DAC (digital-analog converter). The ring signal source stores various sounds at transceiver and terminal. The ring signal speaker transmits ring signal provided by the ring signal source at in detecting ring signal. The DSP (digital signal processor) encodes and decodes input signal with voice codec. The ADC (analog-digital converter) converts analog signal into digital signal. The DAC (digital-analog converter) converts digital signal into analog signal. The analog signal is provided from microphone of transceiver and the digital signal is provided from voice codec.
An apparatus for volume control in digital telephone in accordance with an embodiment of the present invention includes background noise input part, voice/non-voice discrimination part, input signal amplitude measurement part, and volume control part. The background noise input part collects background noise and converts the noise into digital signals. The voice/non-voice discrimination part receives the collected background noise, discriminates between voice and non-voice, and isolates pure noise. The input signal amplitude measurement part measures amplitude of the isolated pure noise. The volume control part adjusts volume of received sound in accordance with the measured amplitude of the isolated pure noise and provides to speaker at receiver. The received sound is provided from the speech codec.
Preferably, the background noise input part includes a microphone of conventional transceiver and an ADC.
Preferably, the volume control part is equipped with ring signal adjustment capability. The ring signal adjustment capability adjusts ring signal in accordance with the measured amplitude of the isolated pure noise and provides to ring signal speaker.
A method for volume control in digital telephone with DSP (digital signal processor) is provided. A method for volume control in digital telephone with DSP (digital signal processor) in accordance with an embodiment of the present invention includes ring signal adjustment step and received sound adjustment step. The ring signal adjustment step is for setting up a call, measuring background noise, and adjusting amplitude of ring signal in accordance with the measured background noise when a phone call is received at standby state. The received sound adjustment step is for collecting background noise from call-start to call-end, measuring amplitude of the background noise, determining level of received sound on the basis of the measured amplitude of the background noise, and adjusting amplitude of received sound.
Preferably, the amplitude of ring signal is determined by following steps. A step is for collecting background noise using microphone at a transceiver. A step is for converting the collected noise into digital signal. A step is for measuring sound pressure level of the digital signal. A step is for comparing sound pressure level of the measured background noise with unique minimum/maximum sound pressure of a digital telephone. A step is for adjusting ring signal volume on the basis of the minimum sound pressure if sound pressure level of the measured background noise is lower than unique minimum sound pressure of a digital telephone. A step is for adjusting ring signal volume on the basis of the maximum sound pressure if sound pressure level of the measured background noise is bigger than unique maximum sound pressure of a digital telephone. A step is for adjusting ring signal volume in proportion to the measured sound pressure level of the measured background noise if sound pressure level of the measured background noise is between the unique minimum sound pressure and the unique maximum sound pressure of a digital telephone.
Preferably, the received sound adjustment step includes following steps. A step is for converting the collected noise into digital signal. A step is for isolating pure noise from transmitting signal by discriminating between voice and non-voice from in the digital signal.
Preferably, the step for determining level of received sound and adjusting amplitude of received sound in the received sound adjustment step employ 10˜30 ms unit as a basic data processing unit.
Preferably, the level of received sound in the received sound adjustment step comprises several stages and is determined by comparing sound pressure of the measured background noise with reference sound pressures of the stages.
Preferably, the step for determining the level of received sound sets the determined level as level for current frame for preventing errors in discriminating between voice and non-voice and frequent change of levels in response to accidental noise if same levels are continued for certain number of frames and level of current frame is changed into different level.
Preferably, the step for determining the level of received sound maintains the level of received sound with input level if the determined level of received sound is higher and lower than the level of previous frame and thereby overflow or underflow is caused in increasing or decreasing volume of received sound.
A method implemented in a computer system for volume control in digital telephone with DSP (digital signal processor) is provided. A method implemented in a computer system for volume control in digital telephone with DSP (digital signal processor) in accordance with an embodiment of the present invention includes ring signal adjustment step and received sound adjustment step.
The ring signal adjustment step includes following steps. A step is for setting up a call. A step is for collecting background noise using microphone at a microphone of a transceiver. A step is for converting the collected noise into digital signal. A step is for measuring sound pressure level of the digital signal. A step is for comparing sound pressure level of the measured background noise with unique minimum/maximum sound pressure of a digital telephone. A step is for adjusting ring signal volume on the basis of the minimum sound pressure if sound pressure level of the measured background noise is lower than unique minimum sound pressure of a digital telephone. A step is for adjusting ring signal volume on the basis of the maximum sound pressure if sound pressure level of the measured background noise is bigger than unique maximum sound pressure of a digital telephone. A step is for adjusting ring signal volume in proportion to the measured sound pressure level of the measured background noise if sound pressure level of the measured background noise is between the unique minimum sound pressure and the unique maximum sound pressure of a digital telephone
The received sound adjustment step includes following steps. A step is for collecting background noise from call-start to call-end. A step is for converting the collected noise into digital signal. A step is for isolating pure noise from transmitting signal by discriminating between voice and non-voice from in the digital signal. A step is for measuring sound pressure level of the pure noise. A step is for determining level of received sound on the basis of the measured sound pressure of the background noise. A step is for adjusting amplitude of the received sound.
BRIEF DESCRIPTION OF THE DRAWINGS
The embodiments of the present invention will be explained with reference to the accompanying drawings, in which:
FIG. 1 is a diagram illustrating structure of a conventional digital telephone;
FIG. 2 is a diagram illustrating structure of a digital telephone in accordance with an embodiment of the present invention;
FIG. 3 is a flow diagram illustrating a ring signal/volume of received sound control method in accordance with an embodiment of the present invention;
FIG. 4 is a flow diagram illustrating the received sound volume adjustment step shown in FIG. 3 in detail;
FIG. 5 is a diagram illustrating call processing at ISDN (integrated service digital network);
FIG. 6 is a graph illustrating ring signal pressure level; and
FIG. 7 is a program list written in C language illustrating level selection step and volume adjustment step if received sound level is determined “large”.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a diagram illustrating structure of a conventional digital telephone.
As shown in FIG. 1, a digital telephone terminal includes a terminal main body 200 and a transceiver 300 . The terminal main body includes a ring signal source 210 , a ring signal speaker 250 , a DSP (digital signal processor) 220 , a DAC (digital to analog converter) 230 , and an ADC (analog to digital converter). The DSP 220 includes a voice codec and the voice codec includes an encoder 222 and a decoder 221 .
The ring signal source stores various sounds, that is, bell sounds. The ring signal speaker 250 transmits ring signal provided by the ring signal source at in detecting ring signal. The DSP (digital signal processor) 220 encodes and decodes input signal with voice codec. The decoder 221 decodes bitstream supplied from wire or wireless channel 100 . The encoder 222 generates bitstream to wire or wireless channel 100 . The ADC (analog-digital converter) converts analog voice signal into digital signal. The DAC (digital-analog converter) converts digital signal into analog voice signal. The analog signal is provided from microphone of transceiver and the digital signal is provided from voice codec.
In such conventional digital telephone terminals, the apparatus in accordance with an embodiment of the present invention measures background noise and adjust volume of received sound and/or ring signal accordingly. The apparatus is implemented as a function block in the DSP 220 as shown in FIG. 2 . FIG. 2 is a diagram illustrating structure of a digital telephone in accordance with an embodiment of the present invention. An apparatus for volume control in digital telephone in accordance with an embodiment of the present invention includes voice/non-voice discrimination part 223 , input signal amplitude measurement part 224 , and volume control part 225 . The microphone at the transmitter collects background noise and digitizes the collected noise. The voice/non-voice discrimination part receives the collected background noise, discriminates between voice and non-voice, and isolates pure noise. The input signal amplitude measurement part measures amplitude of the isolated pure noise. The volume control part adjusts volume of received sound in accordance with the measured amplitude of the isolated pure noise and provides to speaker at receiver. The received sound is provided from the voice codec.
The ring signal adjustment device in accordance with an embodiment of the present invention doesn't include the voice/non-voice discrimination part since it is used when a call is arrived and then voice of an user is not included in the signal.
The microphone at the transmitter is used as an background noise input part 320 and sound pressure level of the input signal is measured at the input signal amplitude measurement part 224 . The volume control part 225 adjusts ring signal provided from the ring signal source 210 and generates the adjusted sound to the ring signal speaker 250 .
After a call has been set up, the received sound adjustment device in accordance with an embodiment of the present invention employs voice/non-voice discrimination part 223 to discriminate between voice of the user and pure noise. Regarding pure noise, the input signal amplitude measurement part 224 measures sound pressure level and the volume control part 225 adjusts volume of the received sound on the basis of the measured sound pressure level. The speaker 310 at the receiver generates the adjusted signal.
FIG. 3 is a flow diagram illustrating a ring signal/volume of received sound control method in accordance with an embodiment of the present invention.
As shown in FIG. 3, initialization S 1 is performed and then a telephone terminal is in standby state S 2 . When a call is arriver, call setup process is performed. When the call setup process is completed, the telephone terminal generates ring signal.
The method in accordance with an embodiment of the present invention measures background noise at step S 3 after call setup process. The timing for obtaining background noise is described in detail at FIG. 5 . The background noise supplied from the microphone 320 at the transmitter is converted into digital signal by ADC 240 and sound pressure level of the digital signal is measured at the input signal amplitude measurement part 224 .
In measuring sound pressure level, an average value of n frames is used. In each frame, sound pressure level is measured in reference to small sound. Input signal is sampled at 8 kHz and quantized with 16 bit per sample. The range of the value is between −32768 and 32767. Following equation 1 illustrates a mathematical equation deriving sound pressure level from input signal.
spl=20log( A /base) [Equation 1]
In equation 1, base means amplitude of the reference sound. Since small sound is used as the reference sound, base becomes 1 with 16 bit sample. A in equation 1 is amplitude of the digitized input signal and the biggest value is 32768. Regarding each sample, measured sound pressure has a value between 0 and 90 and therefore sound pressure that is actually generated means average value of the frame.
The volume control part 225 adjusts volume of ring signal in accordance with the measured sound pressure.
FIG. 6 is a graph illustrating ring signal pressure level. In FIG. 6, let's supposed that (A+a) is minimum sound pressure level and (B+b) is maximum sound pressure level in accordance with ring signal of the telephone. If the sound pressure level of the measured background noise is smaller than or equal to A, ring signal with (A+a) amplitude is generated. If the sound pressure level of the measured background noise is larger than or equal to B, ring signal with (B+b) amplitude is generated. If the sound pressure level of the measured background noise is bigger than A yet smaller than B, amplitude of ring signal is generated on the basis of the following equation 2. y = ( B - A + b - a B - A ) x + ( aB - bA B - A ) , A ≤ x ≤ B , 5 ≤ b ≤ ( a - 5 ) ≤ 15 [ Equation 2 ]
A, B: determined from unique ring signal amplitude of a telephone
a, b: constants
x: sound pressure of the measured background noise
y: volume of output ring signal
Since sound pressure is log scale based, ring signal that is little bigger than the background noise cannot give discrimination capability to listeners. Therefore, in case of small sound pressure level, higher priority is given to ring signal and lower priority is given to big sound signal. Consequently, listeners feel similar sound pressure difference at large.
At step S 7 through step S 10 , input signal generated from a microphone is analyzed from call-start to call-end. As a result, received sound of the telephone is adjusted to be a larger value in an environment where background noise is big and received sound of the telephone is adjusted to be a smaller value in an environment where background noise is small.
The microphone 320 installed at the transmitter is used for collecting background noise. However, a microphone for onhook call may be used for noise collection. Therefore, additional microphone is not needed.
Input signal provided from the microphone of the telephone sometime includes small amount of background noise and sometimes background noise is mixed with voice signal of a user. In case that voice signal is not included, simply background noise is measured. However, in case that voice signal is mixed with background noise, voice signal may be misunderstood as background noise and it may cause wrong result. Therefore, in order to cover cases in which voice signal is provided with background noise, the voice/non-voice discrimination part 223 performs voice/non-voice detection algorithm.
Several methods have been proposed in the area of voice/non-voice detection algorithm. In an embodiment of the present invention, signal is sampled in 8 kHz in digital domain and quantized in 16 bit/sample. Voice signal and background noise are discriminated by a voice/non-voice detection algorithm at step S 7 .
Following technical reports contain information regarding voice/non-voice detection algorithm and an embodiment of the present invention employs the third method proposed by Jung et al.
[1]ITU-T Recommendation G.723.1, ‘Dual rate speech coder for multimedia communications transmitting at 5.3 and 6.3 kbit/s,’ March 1996
[2]U.S. Philips Corporation, ‘Method and device for voice activity detection and a communication device,’ Patent No. 5963901, Oct. 1999.
[3] Woosung Jung, Sangwon Kang, Hosang Sung, Insung Lee, Jaewon Kim, and Songin Choi, “Design of a variable rate speech codec for the W-CDMA system,” KSCSP′98, Vol.15, No.1, pp.142-147.
The input signal amplitude measurement part 224 measures sound pressure for the measured pure background noise at step S 8 . After sound pressure is measured, volume of the received sound is optimized through level selection step, volume adjustment step, and hangover application step at step S 9 . As shown in FIG. 5, this process is continued from call-start to call-end.
In adjusting volume of received sound through level selection step and volume adjustment step, basic data processing unit is 10˜30 ms. Minimum for obtaining vocal data is 10 ms.
Maximum size is 30 ms since frame size of codec used in digital telephones is smaller than 30 ms. Therefore, actual data processing unit for system implementation is represented as d and it is named frame size. All level selection is performed with d.
FIG. 4 is a flow diagram illustrating the received sound volume adjustment step shown in FIG. 3 in detail.
In case that a frame for obtaining sound pressure level is determined as voice of a user and background noise cannot be measured, level of the previous frame is maintained at step S 11 and S 12 .
Level selection is composed of multiple stages, for example, three stages and a level is determined by comparing level pressure of non-voice part with reference sound pressure of each stage at step S 13 .
For example, received sound may be divided into three levels, “small”, “medium”, and “large”. Once an average sound pressure is determined in accordance with the equation 1, level selection in detail may be implemented as follows. If average sound pressure is bigger than 60 dB, output level is set as “large”. Otherwise, all levels are set as “medium”. This standard may be modified by listening experiment. If received sound is determined as “medium”, volume control part 225 passes the signal as the decoder 221 generates.
Now, hangover application process from step S 14 to step S 16 is described.
A reason for hangover application is that users may complain volume of received sound when voice/non-voice discrimination is temporarily failed and levels are continuously changed in response to accidental noise.
Hangover is applied only if levels are changed. When same level is determined for a certain number of frames, a level determined at step 13 is set as current frame's level at step S 15 .
For example, when level is changed from “medium” to “large” or “small”, changed from “large” or “small” to “medium”, or changed from “small” to “large” or “medium” and same level is determined for a certain amount of time, for example, 200˜500 ms, the determined level is set as current frame's level. 200˜500 ms means 7˜17 frames for ITU-T G.723.1 voice codec and therefore same level has to be determined for 7˜17 frames to set the determined level as current frame's level.
In the flow diagram of FIG. 4, a case in which same level is determined for three frames and the determined level is set as current frame's level is illustrated.
If same level is not determined for certain frames or an intermediate frame is determined as a voice frame, count is reset and the value of previous level is maintained.
Using the determined current level, volume of received sound is adjusted at step S 17 .
In adjusting volume of received sound, if underflow or overflow is occurred for a certain number of samples, output of the decoder 221 is directly generated. That is, volume of received sound is not controlled.
For example, if volume of received sound is determined “small”, signal generated at the decoder 221 is shifted 1 bit to right direction and therefore amplitude of output voice is reduced by half. Likewise, if volume of received sound is determined “large”, signal generated at the decoder 221 is shifted 1 bit to left direction and therefore amplitude of output voice is doubled. If volume of received sound is determined “medium”, signal generated at the decoder 221 is directly provided.
At “large” level, if an overflow is caused at output voice of the volume control part 225 , the level is returned to “medium”. This level return occurs when overflows are happened for certain number of samples, for example, 2 samples out of 5 samples. The reason for this is that impulse may be caused by noise.
FIG. 7 is a program list written in C language illustrating level selection step and volume adjustment step if received sound level is determined “large”. At “small” level, if an underflow is caused at output voice of the volume control part 225 , the level is returned to “medium”. Underflow means the case in which amplitude of the sample is below 10 and this level return occurs when underflows are happened for certain number of samples, for example, 2 samples out of 5 samples. Regardless of frame size, if happened in a frame, these two level returns restore the level at the moment.
As described above, an embodiment of the present invention automatically controls ring signal and/or volume of received sound in response to background noise. Therefore, it increases convenience of users and causes effect of adding values.
Also, since an embodiment of the present invention utilizes features already equipped for conventional digital telephones without adding any additional hardware, it is competitive in terms of cost and may be applied to any type of digital telephone.
Although representative embodiments of the present invention have been disclosed for illustrative purpose, those who are skilled in the art will appreciate that various modifications, additions and substitutions are possible without departing from the scope and spirit of the present invention as defined in the accompanying claims. | The present invention relates to an apparatus and a method for volume control in digital telephones such as second generation mobile telephone terminals, third generation IMT 2000 image mobile telephone terminals, and ISDN (integrated service digital network) terminals. In particular, an apparatus and a method in accordance with an embodiment of the present invention measure background noise and adjust volume of received sound and/or ring signal accordingly. An embodiment of the present invention measures background noise before ringing ring signal and adjusts volume of ring signal. While communicating, the apparatus automatically adjusts volume of received sound in response to the measured background noise. A telephone terminal in accordance with an embodiment of the present invention includes voice/non-voice determination part, volume measurement part, and gain control part. The voice/non-voice determination part separates pure background noise from composite signal (voice+background noise). The volume measurement part measures amplitude of the background noise. The gain control part adjusts volume of received sound in response to the measured results. Signal processing is performed in digital domain and DSP is employed. Consequently, the digital telephone in accordance with an embodiment of the present invention is able to prevent noise pollution usually caused by loud ring signal and provide optimized volume for telephone users. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] There are no prior applications related to this application, and no claim is made to any prior document.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention is not subject to any requirement to assign any part or interest to the US Government. It was not developed according to any federal sponsorship, nor was there any research conducted under federally sponsored research or development.
FIELD OF THE INVENTION
[0003] The invention relates to display structures, storage structures, hideaways, secret compartments, tree-like displays, assemblies, freestanding storage structures, holiday decorations, collapsible structures, and stackable assemblies.
BACKGROUND OF THE INVENTION
[0004] There exists in several gift giving holidays a need to provide festive displays or a temporary location for gifts. In particular, a common practice is that of a seasonally erected and decoration of a tree, such as the celebration of Christmas. These displays frequently appear in private homes, social gatherings, offices, and even commercial areas such as shopping malls or offices.
[0005] One common practice is to decorate such trees with strings of lights, small toys, holiday signs, photographs, shiny or brightly colored objects, and any other object which is suitable to retainment on such a tree. The entire category of such objects is broadly referred to as “Christmas tree ornaments.” Another common practice with respect to such holidays is to dedicate an area as a temporary gift-holding area until an appropriate time of dissemination. Lastly, another common practice in the field is to provide the functional and aesthetic value of a tree through use of an artificial tree.
[0006] Artificial trees have numerous advantages over a natural tree. Many can be collapsed and stored, do not decay or fall apart, and are less likely to be a fire hazard. However, there are problems in natural trees that remain persistent problems in the field of artificial trees. Predominantly across the art, the only place for storage of objects is in the space between the supporting surface and the lowest rung of branches of the tree. This can be a very difficult and inconvenient place to reach. It also does little to aid people who are tempted to open presents to resist the urge to peek or even open and use such gifts. There remains the limitation that providing a treelike appearance requires conceding the internal volume of the assembly as being necessarily dedicated as solely inaccessible structure of the plant.
[0007] These persistent problems of the art therefore provide several objects of the invention.
[0008] It is an object of the invention to provide a structure which has the ornamental appearance of a tree.
[0009] It is a further object of the invention to provide a structure which provides areas for storage or display of objects.
[0010] It is a further object of the invention to provide a structure which is easily collapsible for storage or otherwise being moved.
BRIEF SUMMARY OF THE INVENTION
[0011] The invention achieves the stated objects of the invention by providing an assembly configurable to provide an ornamental appearance of a tree while also providing areas within the assembly for objects to facilitate either displaying objects or hiding them. It also provides for configurability into a compact assembly which is sufficiently small so as to be easier to store or otherwise put in a collapsed position.
[0012] The assembly comprises a plurality of stackable spools. When assembled, each spool provides its own area capable of receiving objects. Such objects can include decorations or gifts or other things which are desirable to site within the structure or retain by connection to an element within the assembly. To provide the desirable ornamental appearance, each spool is adapted to receive ornamental elements. To provide an ornamental appearance of a tree, any or all of the plurality of spools can be fitted with tree-like elements, such as a branch or branches. To provide the appearance of a tree or other shape of configuring the assembly, the spools may be fitted with a cover. Such a cover can in whole or in part occlude view of the area of a spool for receiving objects. Contemplated covers include ones which, like spools which comprise branches, also provide an ornamental appearance of a tree. For purposes of considering the broadest set of elements that provide ornamental appearance of a tree, any cover 34 applied to the assembly should also be considered a type of ornamental element.
[0013] To further provide the appearance of a tree, the assembly may also include a cap, the cap providing the assembly with a top piece that provides the ornamental appearance of the very top of a tree.
[0014] The assembly is variously configurable according to the preferences of a user. All spools are capable of being configured as any type of spool without interference with the function of any other spool of the assembly. While the objects of the invention include the desire to provide the appearance of a tree, the assembly is also configurable to achieve other shapes with a tapered overall appearance.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0015] FIG. 1 shows a front elevation of an assembly having the appearance of a tree.
[0016] FIG. 2 shows a front elevation of an assembly having the appearance of a tree with an open shelf portion.
[0017] FIG. 3 shows components of an assembly spaced apart and showing method of assembly.
[0018] FIG. 4 shows a sectioned front elevation of an assembly having the appearance of a tree with an open shelf portion.
[0019] FIG. 5 shows a sectioned front elevation view of an assembly having the appearance of a tree, showing internal components.
[0020] FIG. 6 shows several high-angle front views of an assembly in an erect position,
[0021] FIG. 6A shows a sectioned high-angle front view of an assembly in an erect position.
[0022] FIG. 6B shows a high-angle front view of a supporting post of an assembly in an erect position.
[0023] FIG. 6C shows a sectioned high-angle front view of stacking spools of an assembly stacked in a collapsed position.
[0024] FIG. 6D shows a sectioned high-angle front view of a supporting post of an assembly in a collapsed position.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Referring now to FIG. 1 , shown is the assembly 10 comprising a support 26 , a post 12 and a plurality of spools 14 . Each spool 14 is an incremental progression from bottom to top. Spools which are towards the lower end of the tree are “prior” spools and each of the spools which are successively higher up in the assembly are “successive” spools. The assembly as shown in FIG. 1 has the appearance of a tree, though the invention inventor contemplates other embodiments which are not limited to the shape of the tree.
[0026] Referring now to FIGS. 1, 2, 4, and 5 , there is shown various front elevation views of the assembly in an erected position, having the appearance of a tree. The tree successively comprises a support 26 , a post, 12 , a flange 24 , a plurality of successive spools 14 , and a cap 30 . With respect to FIGS. 4-6 , four successive spools are visible, though the invention is capable of configuration with an assembly of unlimited value quantity of such spools. Each spool comprises a shelf element 32 , and they cumulatively comprise a variety of features, including but not limited to an ornamental element 40 , a cover 34 , and an open area 36 .
[0027] Referring to FIG. 3 , each spool comprises an open region 16 , a bottom most diameter 20 , and a uppermost diameter 22 . In all of the spools shown in FIG. 3 , the bottom most diameter is larger than the top most diameter.
[0028] FIGS. 4 and 5 show sectioned front views of the assembly in alternative erected configurations. There is a plurality of spools that are stacked successively, along the direction from the support 26 toward the cap 30 . The spools are aligned to a central post 12 , the post being arranged to an upright position by the support 26 . Each of the plurality of spools 14 is successively applied atop a prior spool.
[0029] For the embodiments shown in FIGS. 1, 2, 4 and 5 , the bottom most diameter of each successive spool is smaller than the bottom most diameter of the prior spool. Cumulatively, the progression from larger bottom most diameters of prior spool's toward smaller bottom most diameters of successive spools provides the shown embodiments with a tapering overall ornamental shape. FIG. 1 depicts an embodiment that is configured with such ornamental elements and fully assembled to provide 0 the ornamental appearance of a tree. In FIG. 2 the assembly is also configured and assembled to provide the ornamental appearance of a tree, but one of the plurality of spools 14 does not comprise any ornamental element, and shows an area 36 atop a shelf portion of one of the spools.
[0030] In FIG. 4 , each area 36 is configured to accommodate the placement of ornamental or gift or other items within the ornamental profile of the assembly in a space bound by the bottom most diameter of a spool and the top most diameter of that spool, while in FIG. 5 , it is defined by the bottom most diameter of a spool and the bottom most diameter of the immediately successive spool.
[0031] The assemblies of FIGS. 4 and 5 depict spools each having ornamental elements that provide embodiments of the assembly with the overall ornamental appearance of a tree. FIG. 5 's ornamental element being each and any of the covers 34 , while FIG. 4 's assembly comprises a spool which comprises at least one branch as its ornamental element 40 . The ornamental element 40 shown in FIG. 4 is also visible in FIG. 2 , sited on the spool labeled 14 c . That spool 14 c comprises a plurality of ornamental elements which occupy at least a portion of its open area 36 . Another ornamental element shown in all figures is any instance of a cover 34 . In FIGS. 1, 2, 4 , and 6 , each cover 34 extends from approximately the position of the bottommost shelf portion of a spool to the bottommost shelf portion of a prior spool. In FIGS. 4 and 5 , at least one of the plurality of spools 14 shows a cover 34 assembled to at least extend vertically approximately from the position of the bottom most diameter of a spool to the bottom most diameter of the immediately prior spool. The distance covered between the bottom diameters covered defines the height of the area 36 , covering at least a portion of the shelf portion 32 , and at least partially enclosing/covering the area 36 . Both FIG. 4 and FIG. 5 show a post 12 which aligns the spools 14 . The post 12 in FIG. 4 has a continuous diameter along its length. FIG. 5 shows an alternative embodiment of a post 12 that has a stepwise progressively smaller diameter in the direction from the support 26 toward the cap 30 . FIG. 6 also shows the post 12 of FIG. 5 in an erect position, supporting spools in FIG. 6A , and the post 12 standing in isolation in FIG. 6B . FIG. 6D shows the post 12 common to FIGS. 5 and 6 in a collapsed position, with each of its stepwise diameter sections concentrically retained within the support 26 . In FIGS. 5 and 6 , it is shown that, in order to engage the stepwise progressively smaller diameters of the post 12 , the open regions 16 for each of successive spool has a correspondingly smaller internal diameter than the immediately prior spool.
[0032] Referring to FIG. 6C , The spools 14 and each of their respective covers 34 are shown in a compact/collapsed/stowed position, wherein the successive spools are stacked in reversed order, with a prior spool atop a successive spool. The stepwise larger diameter of the open region 16 of each successive spool is large enough to concentrically and nestably receive a prior spool. In so doing, each spool with a larger bottommost diameter is stacked atop a spool of smaller bottommost diameter. Each cover 34 for each spool, according to the successively smaller bottom most diameters of the spools 14 is therefore also sized to allow each to fit concentrically within the cover 34 for each successive spool. Therefore, the entire set of spools 14 shown in FIG. 6C is able to consume a much smaller vertical distance than the height of the post 12 in its erected position (as shown in FIGS. 5, 6A, and 6B ), and as compared to when the same spools 14 are stacked in successive order. | A vertically stacking assembly for retainment of objects for hiding from view or displaying of the objects at incremental heights, providing selectably configurable appearance for discrete stacking components, and which is collapsible for storage or relocation. It supports configuration so as to provide an ornamental appearance of a tree or other shape which preferably tapers to progressively smaller diameter with increasing height. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a hinge mechanism of a fluid displacement apparatus. More particularly, it relates to a configuration of a hinge mechanism of a swash plate-type refrigerant compressor for use in automotive air conditioning systems.
2. Description of the Related Art
Generally, the compressor of an automobile air conditioner is driven by the engine of the automobile. The rotation frequency of the drive mechanism of the engine changes with time. The refrigerant capacity changes in proportion to the rotation frequency of the engine. Because the capacity of the evaporator and the condenser of the air conditioner does not change, when the compressor is driven at high rotation frequency, the compressor performs inefficiently. To avoid inefficiency, existing automobile air conditioning compressors are controlled by intermittent operation of the magnetic clutch. However, this results in a large load being intermittently applied to the automobile engine,
One solution, to above mentioned problem is to control the capacity of the compressor in response to refrigeration requirements. One embodiment adjusts the capacity of a compressor, particularly a wobble plate-type compressor, as disclosed in the U.S. Pat. No. 4,664,604 to Terauchi. With reference to FIGS. 1 and 2, a refrigerant compressor includes a closed cylinder housing assembly 100 formed by annular casing 21, which has a cylinder block 23 and a hollow portion with a crank chamber 15, a front end plate 20, and a rear end plate 22. Front end plate 20 is mounted on the left end opening of annular casing 21 and closes the end of crank chamber 15. Front end plate 20 is fixed on annular casing 21 by a plurality of bolts (not shown). Rear end plate 22 and valve plate 24 are mounted on the opposite end of casing 21 by a plurality of bolts (not shown) to cover the end portion of cylinder block 23. An opening 20a is formed in front end plate 20 and receives drive shaft 3. An annular sleeve 20b projects from the front end surface of front end plate 20 and surrounds drive shaft 3 to define a shaft seal cavity 199. A drive shaft seal assembly 202 is assembled on drive shaft 3 within shaft seal cavity 199.
Drive shaft 3 is rotatable and supported by front end plate 20 through bearing 200. Bearing 200 disposed within opening 20a. The inner end of drive shaft 3 is provided with a rotor plate 9. Thrust needle bearing 201 is placed between the inner surface of front end plate 20 and the adjacent axial surface of rotor plate 9 to receive thrust load that acts against rotor plate 9. Thrust needle bearing 201 ensures smooth motion. The outer end of drive shaft 3 extends outwardly from sleeve 20b and is driven by the engine of a vehicle through a conventional pulley arrangement. The inner end of drive shaft 3 extends into a central bore 230 in the center portion of cylinder block 23 and is rotatably supported by a bearing, such as radial needle bearing 232. The axial position of drive shaft 3 may be adjusted by adjusting screw 233, which is screwed into a threaded portion of central bore 230. A spring device 234 is disposed between the axial end surface of drive shaft 3 and adjusting screw 233. A thrust needle bearing 235 is placed between drive shaft 3 and spring device 235 to ensure smooth rotation of drive shaft 3.
A spherical bush 8 is placed between rotor plate 9 and cylinder block 23. Spherical bush 8 may be slidably carried on drive shaft 3. Spherical bush 8 supports a slant or swash plate 4 for nutational (wobble) and rotational motion. A coil spring 10 surrounds drive shaft 3 and is placed between the end of rotor plate 9 and one axial surface of spherical bush 8 to push spherical bush 8 toward cylinder block 23.
Swash plate 4 is connected to rotor plate 9 with a hinge coupling mechanism that rotates in unison with rotor plate 9. Rotor plate 9 has an arm portion 9a projecting axially outward from one side surface. Swash plate 4 also has second arm portion 13 projecting toward arm portion 9a of rotor plate 9 from one side surface. As depicted in FIG. 1, second arm portion 13 is formed separately from swash plate 4 and is fixed on one side surface of swash plate 4. Arm portions 9a and 13 overlap each other and are connected to one another by a pin 11. Pin 11 extends into a rectangular shaped hole 13a, and into arm portion 9a of rotor plate 9. Pin hole 13a is formed through second arm portion 13 of swash plate 4. Thus, rotor plate 9 and swash plate 4 are hinged together. Pin 11 is slidably disposed in rectangular hole 13a. The sliding motion of pin 11 within rectangular hole 13a changes the slant angle of the inclined surface of swash plate 4.
Cylinder block 23 has a plurality of annular arranged cylinders 231 wherein pistons 50 slide. A typical arrangement may have five cylinders 231, but a different number of cylinders 231 may be provided. Each piston 50 comprises a head portion 50a slidably disposed within one of cylinders 231, a hollow portion 50b formed within head portion 50a, a connecting portion 52 and a rod portion 51. Rod portion 51 joins head portion 50a to connecting portion 52. Connecting portion 52 of piston 50 has a cutout portion 52a which straddles the outer peripheral portion of swash plate 4. Semi-spherical thrust bearing shoes 6 are disposed on each side of swash plate 4 and face the inner surface of connecting portion 52. This allows for sliding along the side surface of swash plate 4. The rotation of drive shaft 3 causes the swash plate 4 to rotate between bearing shoes 6 and to move the inclined surface axially to the right and left. The rotation of drive shaft 3 also reciprocates each piston 50 within cylinders 231.
Rear end plate 22 encloses a suction chamber 220 and discharge chamber 221. Valve plate member 24 and rear end plate 22 are fastened to cylinder block 23 by screws. A plurality of valved suction ports 24a may be connected between suction chamber 220 and cylinders 231, and a plurality of valved discharge ports 24b may be connected between discharge chamber 221 and cylinders 231. Gaskets 32 and 33 are placed between cylinder block 23 and valve plate 24, and between valve plate 24 and rear end plate 22, and seal the matching surfaces of cylinder block 23, valve plate 24 and rear end plate 22.
Further, another wobble plate compressor is disclosed in U.S. Pat. No. 5,165,863 to Taguchi. Referring to FIG. 2, compressor 500 includes cylindrical housing assembly 502 having a cylinder block 502a and a front housing 503 disposed at one end of cylinder block 502a. A crank chamber 510 is enclosed within cylinder block 502a by front housing 503. Rear end plate 531 is forward of crank chamber 510 and attached at the opposite end of cylinder block 502a by a plurality of bolts (not shown). Valve plate 530 is located between rear end plate 531 and cylinder block 502a. Opening 503a is centrally formed in front housing 503 for supporting drive shaft 509 with bearing 508 disposed therein. The inner portion of drive shaft 509 is disposed within the central bore of cylinder block 502a and rotatably supported by bearing 507. Bore 502c extends to the rear surface of cylinder block 502a.
Cam rotor 511 is fixed on drive shaft 509 by a pin member (not shown) and rotates with drive shaft 509. Thrust needle bearing 505 is disposed between the inner end surface of front housing 503 and the adjacent axial end surface of cam rotor 511. Cam rotor 511 has an arm 511b with a pin member 511a extending therefrom. Slant plate 513 is adjacent to cam rotor 511 and has an opening 513a. Drive shaft 509 is disposed through opening 513a. Slant plate 513 comprises an arm 512 having a slot 512a. Cam rotor 511 and slant plate 513 are connected by a pin member 511a. Pin member 511a is inserted in slot 512a to create a hinge joint, which connects cam rotor 511 and slant plate 513. Pin member 511a slides within slot 512a to allow adjustment of the angular position of slant plate 513 with respect to a plane perpendicular to the longitudinal axis of drive shaft 509.
Wobble plate 516 is nutatably mounted on hub 520 of slant plate 513 through bearings 517 and 518. Thus, slant plate 513 rotates with respect to wobble plate 516. Fork-shaped slider 525 is attached to a radially outer peripheral end of wobble plate 516 and is mounted on a sliding rail 524. Sliding rail 524 is disposed between front housing 503 and cylinder block 502a. Fork-shaped slider 525 prevents the rotation of wobble plate 516 when wobble plate 516 nutates along rail 524. Cylinder block 502a may have a plurality of cylinder chambers 522 wherein pistons 523 are disposed. Each of pistons 523 is connected to wobble plate 516 by a corresponding connection rod 515. Accordingly, nutation of wobble plate 516 causes pistons 523 to reciprocate within their respective chambers 522.
Rear end plate 531 may have a peripherally located annular suction chamber 532 and a centrally located discharge chamber 538. Valve plate 530 may have a plurality of valved suction ports 534 linking suction chamber 532 with cylinder chambers 522. Valve plate 530 has a plurality of valve discharge ports 535 linking a discharge chamber 533 with cylinder chambers 522. Suction ports 534 and discharge ports 535 are provided with suitable reed valves (not shown).
Suction chamber 532 may have an inlet portion (not shown) of an external cooling circuit. Discharge chamber 533 may have an outlet portion (not shown) connected to a condenser (not shown) of the cooling circuit. A valve retainer 536 is fixed on a central region of the outer surface of valve plate 530 by bolts 537 and nut 538. Valve retainer 536 prevents excessive bend of the reed valve at discharge port 535 during compression strokes of piston 523. Rear end plate 531 has a capacity control mechanism 540 disposed within a space 542. Capacity control mechanism 540 controls the pressure of crank chamber 510 by regulating the volume of discharge gas that is introduced into the crank chamber 510. The stroke length of the pistons, and, thus, the capacity of the compressor, may be changed by adjusting the slant angle of the wobble plate. The slant angle is changed in response to the pressure differential between the suction chamber and the crank chamber.
Compressors 100 and 500 in the above-mentioned references have elongated slots 13a and 512a formed in arms 13 and 512, respectively. Arms 13 and 512 are connected to rotor 9 of swash plate 4 and rotor 511 of slant plate 513. Further, rotors 9 and 511 are coupled with swash plate 4 and slant plate 513, such that pins 11 and 511a may be slidably disposed in slots 13a and 512a by employing a washer member. Therefore, the arrangements are fairly complex in production. Further, because elongated slots 13a and 512a are formed by a piercing process with machinery, this arrangement is not simple to manufacture and has a high assembling cost.
Further, during the compression and suction stages of these compressors, pins 11 and 511a are axially subjected to the compression reaction force from the pistons. Thus, it is undesirable that bush 8 and cylindrical sleeve 555 are axially subjected to the excessive force, although bush 8 and cylindrical sleeve 555 are supported by the compression reaction force.
One approach to resolve the problem is to expand the widths of elongated slots 13a and 512a in order to intensify the engaging between pins 11/511a and slots 13a/512a. However, expanding the widths of elongated slots 13a and 512a is limited by the design of the compressor.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a fluid displacement apparatus with a hinge mechanism.
It is another object of the present invention to provide a fluid displacement apparatus which may be assembled at a reduced cost.
It is a further object of the present invention to provide a fluid displacement apparatus which generates reduced noise and vibration during operations.
According to the present invention, a fluid displacement apparatus comprises a housing enclosing a crank chamber, a suction chamber and a discharge chamber. A plurality of cylinders are formed in the housing. A plurality of pistons, wherein each is slidably disposed within one of the cylinders such that the piston reciprocates within the cylinder. A drive shaft is rotatably supported in the housing. A cam rotor is fixedly connected to the drive shaft and has a first arm extending therefrom. A plate is tiltably connected to the drive shaft. The plate has a surface disposed at an adjustable inclined angle relative to a plane perpendicular to the drive shaft and has a second arm extending therefrom. A coupling means couples the plate to the pistons such that the pistons are driven in a reciprocating motion within the cylinders upon nutation of the plate. A pin member is disposed in the second arm of the plate. An engaging device is disposed within the cam rotor. The pin member is slidably disposed within the engaging device, such that the cam rotor is coupled to the slant angle for permitting a variable inclination of the slant plate to vary.
Further objects, features, and advantages of this invention will be understood from the following detailed description of preferred embodiments with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and its advantages, reference is now made to the following description taken in conjunction with the accompanying drawings, wherein like reference numerals represent like parts.
FIG. 1 is a longitudinal cross-section view of a swash plate type refrigerant compressor in accordance with prior art.
FIG. 2 is a longitudinal cross-section view of a swash plate type refrigerant compressor in accordance with prior art.
FIG. 3 is a longitudinal cross-section view of a swash plate refrigerant compressor in accordance with a first embodiment of the present invention.
FIG. 4 is an exploded view of a hinge mechanism used in a swash plate refrigerant compressor in accordance with the first embodiment of the present invention.
FIG. 5 is a partial, cross-section view of a hinge mechanism used in a swash plate refrigerant compressor in accordance with a second embodiment of the present invention.
FIG. 6 is a partial, cross-section view of a hinge mechanism used in a swash plate refrigerant compressor in accordance with a third embodiment of the present invention.
FIG. 7 is a partial, cross-section view of a hinge mechanism used in a swash plate refrigerant compressor in accordance with a fourth embodiment of the present invention.
FIG. 8 is an exploded view of a cap member and pin member of a hinge mechanism used in a swash plate refrigerant compressor in accordance with the fourth embodiment of the present invention.
FIG. 9 is a partial, cross-section view of a hinge mechanism used in a swash plate refrigerant compressor in accordance with a fifth embodiment of the present invention.
FIG. 10 is a partial, cross-section view of a hinge mechanism used in a swash plate refrigerant compressor in accordance with a sixth embodiment of the present invention.
FIG. 11 is an exploded view of a pin member of a hinge mechanism used in a swash plate refrigerant compressor in accordance with the sixth embodiment of the present invention.
FIG. 12 is a partial, cross-section view of a hinge mechanism used in a swash plate refrigerant compressor in accordance with a seventh embodiment of the present invention.
FIG. 13 is an exploded view of a pin member of a hinge mechanism used in a swash plate refrigerant compressor in accordance with the seventh embodiment of the present invention.
FIG. 14 is a longitudinal cross-section view of a swash plate refrigerant compressor in accordance with an eighth embodiment of the present invention.
FIG. 15 is an exploded view of a hinge mechanism used in a swash plate refrigerant compressor in accordance with the eighth embodiment of the present invention.
FIG. 16 is a partial, cross-section view of a hinge mechanism used in a swash plate refrigerant compressor in accordance with a ninth embodiment of the present invention.
FIG. 17 is a longitudinal cross-section view of a swash plate refrigerant compressor in accordance with the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The embodiments of the present invention are illustrated in FIGS. 3-17 wherein like numerals are used to denote elements which correspond to like elements depicted in FIGS. 1 and 2. A detailed explanation of several elements and characteristics of prior art compressors is provided above and, therefore, is omitted from this section.
Referring to FIGS. 3 and 4, an arm 113 extends from an end surface of swash plate 4. An arm portion 113a, which is defined by one end of arm 113, has pin members 111. Pin members 111 extend perpendicularly from radial side surfaces 113c and 113d of arm 113.
Rotor 109, which faces arm 113, has arms 109a and 109b formed at the edge of arm 113. Arms 109a and 109b engage with pin members 111. Arms 109a and 109b have grooves 129 and 130, respectively, that face each other. Grooves 129 and 130 have a half circle shape with an axial cross section. Pin members 111 engage to grooves 129 and 130 and is slidably disposed within grooves 129 and 130.
Referring to FIG. 4, the thickness of arms 109a and 109b of rotor 109 may be defined by "L". The size of the longitudinal axis of grooves 129 and 130 may be equal to thickness "L" of arms 109a and 109b, respectively.
In an embodiment, drive shaft 3 is rotated by a vehicle engine through a pulley arrangement. Rotor plate 109 is rotated with drive shaft 3. The rotation of rotor plate 109 is transferred to swash plate 4 by the hinge mechanism. Thus, the inclined surface of swash plate 4 moves axially to the right and left with the respect to the rotation of rotor plate 109. Torque transmitted from drive shaft 3 via the engine (not shown) is delivered to swash plate 4 for its nutational and rotational motion, accordingly. Arm 113 couples to rotor 109, such that pin members 111 engage to grooves 129 and 130. Pin members 111 are pinched and disposed between arms 109a and 109b of rotor 109, such that grooves 129 and 130 limit the locus of motion of swash plate 4. Piston 50 is connected to swash plate 4 by bearing shoes 6. Thus, piston 50 reciprocates within cylinder 231. As piston 50 reciprocates, refrigerant gas is introduced into suction chamber 220 from a fluid inlet port 22a, taken into cylinders 231 through suction ports 24a, and compressed. The compressed refrigerant is discharged through discharge ports 24b into discharge chamber 221 from cylinders 231. The compressed refrigerant is then released into an external fluid circuit, such as a cooling circuit through the fluid outlet port (not shown).
Thus, production of the hinge mechanism may be accomplished without an elongated slot formed in the arm portion of the swash plate and a snap ring. Further, assembly costs may be reduced because the arrangement has a hinge mechanism that has a pin and grooves. In contrast, an elongated slot may require a piercing process, which may incur higher costs. Further, during the compression and suction stage of the compressors, pin members 111 are axially subjected to the compression reaction force from piston 50. Further, the width of the groove of the arm of the rotor may be expanded in order to strengthen the engagement between pin members and the grooves.
FIG. 5 depicts a second preferred embodiment of the present invention. Arm portion 113a of arm 113 includes a hole 113d. Hole 113d penetrates from radial side surface 113b to radial side surface 113c of arm 113. A plurality of pin members 114 are inserted into both ends of hole 113d. Pin members 114 may be cylindrical in shape and have a cylindrical body 114a, a head portion 114b, and a flange 114c between cylindrical body portion 114a and head portion 114b. Flanges 114c of pin members 114 extends radially from the periphery surface of pin members 114. Pin members 114 may be inserted into hole 113d until flanges 114c strikes against radial side surfaces 113c and 113d of arm 113. Thus, pin members 114 protrude from radial side surfaces 113c and 113d of armn 113.
Noise and vibration may be caused by the gap created between hinge joint mechanism that joins arms 109a and 109b of rotor 109 to arm 113 of swash plate 4. This embodiment may reduce the noise and vibration because the semi-spherical surface of pin members 114 of swash plate 4 is in contact with the bottom surface of the groove of rotor 109.
FIG. 6 depicts a third embodiment of the present invention. A pin member 115 is inserted into hole 113d. Pin member 115 may be a cylindrical shape with a cylindrical body 115a and a head portion 115b formed at the both ends. Head portions 115b have a beveling at the edge corner for engaging along a curved bottom surface of grooves 129 and 130. Head portions 115b of pin member 115 protrude from radial side surface 113b and radial side surface 113c, respectively. A plurality of ring washers 116 encircle head portions 115b of pin member 115, such that head portions 115b penetrate openings of washers 116.
FIGS. 7 and 8 depict a fourth embodiment of the present invention. Pin member 117 has a cylindrical body 117a and head portions 117b that extend axially from both ends of cylindrical body 117a. Head portions 117b may have an outside diameter smaller than that of cylindrical body 117a. A pin member 117 may be inserted into hole 113b such that head portions 117b protrude from radial side surface 113b and radial side surface 113c, respectively. Cap members 118b, each having a cylindrical body 118a, extend radially from the periphery surface of cylindrical bodies 118a. Opening 118c penetrates through the center of cap members 118. Thus, head portions 117a penetrate through opening 118c of cap members 118. Cylindrical portions 118a of cap members 118 may have a beveling at the edge corner for engaging along a curved bottom surface of grooves 129 and 130. Therefore, cap members 118 engage to grooves 129 and 130 of arm portion 109 so as to be slidably disposed within grooves 129 and 130. Accordingly, cap members 118 are placed between grooves 129a and 130 of arm portion 109.
FIG. 9 depicts a fifth embodiment of the present invention. Arm 113 has a pair of apertures 153 on radial side surface 113b and radial side surface 113c of arm 113. Apertures 153 have a depth to accommodate pin members 119. Pin members 119 may have cylindrical bodies 119a and hemisphere portions 119b. Pin members 119 are inserted into aperture 153 until pin member 119 fill aperture 153.
Hemisphere portions 119b of pin members 119 protrude from radial side surface 113b and radial side surface 113d of arm 113. Each of pin members 119 engages to grooves 129 and 130 of arm portions 109 so as to be slidably disposed within grooves 129 and 130. Further, the distance between a pair of arms 109a and 109b may be greater than the width of arm portion 113a.
FIGS. 10 and 11 depict a sixth embodiment of the present invention. Pin members 120 may have a cylindrical body 120a and a head portion 120b. Head portion 120b may have a C-cut surface 120c or, alternatively, an inclined surface at the corner edge of head portion 120b. Further, engaging portions 109a and 109b may have grooves 429 and 430. Grooves 429 and 430 may have a pair of inclined surfaces 429a and 430a, a pair of bottom flat surfaces 429b and 430b, and a pair of side surfaces 429c and 430c. Thus, grooves 429 and 430 correspond to C-cut surfaces 120c. Pin members 120 engage with grooves 429 and 430. Therefore, rotor 109 is coupled to swash plate 4 through the hinge mechanism composed of pin members 120 and grooves 429 and 430.
FIGS. 12 and 13 depict a seventh embodiment of the present invention. Arms 109a and 109b may have grooves 629 and 630, respectively. Grooves 629 and 630 have inclined surfaces 629a and 630a, bottom flat surfaces 629b and 630b, first side surfaces 629c and 630c, and second side surfaces of 629d and 630d. The shape of grooves 629 and 630 correspond to the shape of head portions 120b of pin members 120. Thus, pin members 120 engage with grooves 629 and 630. Therefore, rotor 109 is coupled to swash plate 4 through the hinge mechanism composed of pin members 120 and grooves 629 and 630.
FIGS. 14 and 15 depict an eighth embodiment of the present invention. In this embodiment, the hinge mechanism is reverse of the one in the embodiments disclosed in FIGS. 1-13. Arm 313 of swash plate 4 may have arm portions 313a and 313b paralleling each other Arm portions 313a and 313b may have grooves 314 and 315, respectively. Grooves 314 and 315 may have a U-shape cross section. Referring to FIG. 15, rotor 309 has an arm 309a. Arm 309a may have pin members 311. Pin members 311 may have a cylindrical body 311a and a head portion 311b. Pin members 311 extend perpendicularly from arm 309a of rotor 309. Thus, pin members 311 are engaged with grooves 314 and 315, such that pin members 311 slide in grooves 314 and 315. Therefore, rotor 309 is coupled to swash plate 4 through the hinge mechanism composed of pin members 311 and grooves 314 and 315 of arm portions 313a and 313b.
FIG. 16 depicts a ninth embodiment of the present invention. Arm 309a of rotor 309 has a hole 309d that penetrates from radial side surface 309b to radial side surface 309c. Pin members 316 are inserted into hole 309d. Pin members 316 may have a cylindrical body 316a, a head portion 316b, and a flange 316c. Flanges 316c of pin members 316 extend radially from the periphery surface of pin members 316. Pin members 316 insert into hole 309d until flange 316c strikes against radial side surfaces 309b and 309c. Thus, pin members 316 protrude from radial side surfaces 309b and 309c.
Referring to FIG. 17, a swash plate compressor is depicted for use in accordance with the present invention. In this embodiment, no bush 8 is placed between swash plate 4 and drive shaft 3, as disclosed in FIG. 3. Swash plate 4 may have a penetrating hole 411 that allows drive shaft 3 to penetrate swash plate 4.
Although the preferred embodiments disclose the invention as a swash plate compressor, the invention is not restricted to swash plate refrigerant compressors, but may be employed in a wobble plate type compressor, or a piston type fluid displacement apparatus with a variable displacement mechanism. Accordingly, the embodiments and features disclosed herein are provided by way of example only. It will be easily understood by those of ordinary skill in the art that variations and modifications can be easily made within the scope of this invention as defined by the following claims. | A fluid displacement apparatus includes a cam rotor connected to a drive shaft and having a first arm extending therefrom. A plate is tiltably connected to the drive shaft. The plate has a surface disposed at an adjustable inclined angle relative to a plane perpendicular to the drive shaft and has a second arm extending therefrom. The plate and the piston are coupled, so that the pistons are driven in reciprocating motion within the cylinders upon nutation of the plate. A pin member is disposed in the second arm of the plate. An engaging device is disposed in the cam rotor. The pin member is slidably disposed in the engaging device, so that the cam rotor is coupled to the slant angle for permitting the inclination of the slant plate to vary. | 5 |
BACKGROUND OF THE INVENTION
A pyrotechnic initiator converts an electrical signal into a controlled output flame. A primer generates a flash and a booster pellet converts the flash into a controlled burn that is provided at an outlet. The flame performs a function, for example ignition of a volume of solid, liquid, or gas propellant.
Current ignition systems, for example as disclosed in U.S. Pat. No. 5,588,366, are designed to ignite solid propellants. In such systems, the reaction generally results in an explosion that is difficult to precisely control, leading to variability in the outcome. When the pyrotechnic is initiated, the outlet region of the propellant chamber disintegrates under the force of the reaction, and the resulting byproducts interfere with the flame. Consequently, the ignition is generally erratic and unpredictable, and therefore burning of the propellant is difficult to control in a repeatable fashion.
With the advent of liquid and gel propellants that have the potential for a more consistent reaction, designers are finding that contemporary chemical ignition systems are inadequate for providing the level of precision required to take full advantage of the advantageous properties of the liquid and gel propellants. Liquid and gel propellants are commonly contained in a reservoir prior to combustion by the igniter in a reaction chamber. For liquid and gel propellants, the igniter performs two functions: displacement of a regenerative piston to initiate propellant injection; and generation of hot, high-pressure gas to ignite the cold liquid/gel propellant as it enters the combustion chamber. The parameters of interest are the rate of rise in pressure (i.e., mass and energy fluxes), the maximum pressure, and the duration of the igniter. Such parameters are tailored to the characteristics of the injection piston and the liquid/gel propellant reservoir, in order to ensure that the reservoir pressure is greater than the reaction chamber pressure when the injector opens. Due to their poor flame distribution, conventional initiators are inadequate for operation with liquid and gel propellants. As a result, designers resort to laser ignition technology, which is highly accurate, but, due to the complex nature of the technology, tends to be cumbersome and expensive, and therefore does not lend itself well to high-volume applications.
SUMMARY OF THE INVENTION
The present invention is directed to a high-precision pyrotechnic initiator well adapted for rapid, precise ignition of all forms of energetics, including liquid and gel energetics. A rigid housing, for example formed of stainless steel, contains a pyrotechnic in a hermetically sealed environment. The reaction of the pyrotechnic is confined to the housing. The release of energy creates a hot particulate in which the formation of solids is mitigated or eliminated. The flame is directed down a microcapillary flash tube including a primary front vent and secondary side vents, which generates a more evenly distributed flame spread, and which increases system efficiency and reliability. A redundant dual bridge wire may also be provided for improving ignition reliability. The assembly thereby performs the combined functions of both an igniter and a flash tube and a complete ignition train is provided in a manner that overcomes the limitations of the conventional configurations. High internal chamber pressure is attained, and superheated particulates are delivered through the vented flash tube, thereby creating a sustained regenerative process, while avoiding long ignition delays. The resulting system of the present invention is therefore suitable for operation with liquid and gel propellants.
A tube, referred to as a flash tube, can be mounted to the outlet for directing the flame, and side vents can be provided on the flash tube for generating a more evenly distributed flame spread about the flash tube.
In one aspect, the present invention is directed to a pyrotechnic initiator. The initiator includes a housing having an inner chamber and an outlet. A pyrotechnic charge is located within the chamber. The housing is of sufficient mechanical integrity to withstand internal pressure of the pyrotechnic charge when activated, such that the internal pressure is released at the outlet.
The pyrotechnic initiator may further comprise a vent tube in communication with the outlet having a longitudinal primary vent for directing activated pyrotechnic charge from the inner chamber through an entrance aperture of the primary vent to an exit aperture. The pyrotechnic initiator may further include lateral secondary side vents in communication with the longitudinal primary vent for directing activated pyrotechnic charge to the side of the vent tube.
A groove may be formed in an outer surface of the vent tube, and an O-ring positioned in the groove, for providing a barrier to escape of initiated pyrotechnic charge between the outer surface of the vent tube and the outlet. The O-ring preferably deforms upon activation of the pyrotechnic charge to seal a gap between the outer surface of the vent tube and the outlet. The width of the O-ring is preferably less than that of the groove to allow for equal distribution of pressure from the initiated charge across a side surface of the O-ring.
The O-ring may comprise first, second and third sub-O-rings positioned adjacent each other in the groove. The first and third sub-O-rings are positioned on opposite sides of the second O-ring, in which case the first and third sub-O-rings comprise Bakelite and wherein the second O-ring comprises Neoprene.
A bridge wire is included for conducting current to initiate activation of the pyrotechnic charge. In one example the bridge wire comprises first and second redundant bridge wires that may be configured in a cross pattern for distribution of the current through the pyrotechnic charge. First and second contact pins pass through the housing and are electrically coupled to corresponding first and second portions of the bridge wire for delivering current to the bridge wires. A pin seal is provided along at least a portion of the bodies of the first and second pins for sealing the interface between the first and second pins and the housing.
A first moisture barrier may be provided at the entrance aperture of the primary vent, for example comprising a fluoropolymeric seal. A retention sleeve, for example comprising nylon, may be provided in the chamber between the pyrotechnic charge and the vent tube for securing the vent tube in the outlet.
The pyrotechnic charge may comprise a material selected from the group of materials consisting of: cis-bis-(5-nitrotetrazolato)tetraminecobalt(III)perchlorate (BNCP), zirconium potassium perchlorate (ZPP), titanium-hydride-potassium-perchlorate (THPP), and lead azide (PbN 6 ).
The housing preferably comprises stainless steel of sufficient structural integrity and/or composition so as to contain the energy released by the pyrotechnic charge when activated. The housing may comprise a plurality of body portions that are welded together to form the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the invention will be apparent from the more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
FIG. 1 is a cross-sectional view of a microcapillary initiator configured in accordance with the present invention in a dormant state, prior to activation.
FIG. 2 is a cross-sectional view of the microcapillary initiator of FIG. 1 during activation, in accordance with the present invention.
FIG. 3A is a cross-sectional closeup view of the region of the O-ring of the microcapillary initiator of FIG. 1 . FIG. 3B is a closeup view of the position of the O-ring prior to activation, while FIG. 3C is a closeup view of the position of the O-ring following activation.
FIG. 4A is a perspective view of the header body illustrating a cross-patterned bridge wire configuration including first and second redundant bridge wires, for improved reliability, in accordance with the present invention.
FIG. 4B is a perspective view of the header body illustrating a parallel bridge wire configuration including first and second redundant bridge wires, for improved reliability, in accordance with the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 is a cross-sectional view of a microcapillary initiator configured in accordance with the present invention, in a dormant state, prior to activation. The initiator 100 includes a housing 18 , for example formed of stainless steel, of sufficient structural integrity for containing the reaction of the pyrotechnic charge when activated. While the housing 18 may comprise a unitary structure, the housing disclosed in FIG. 1 includes multiple components, for ease of manufacturablity and improved reliability. First and second body portions, 20 , 22 respectively may be welded together along stain 21 . An internal housing 30 is seated within the first body portion 20 and a mating header body 32 is seated within the second body portion. A fluoropolymeric sealant may be provided between the internal housing 30 and the first body 20 to prevent migration of moisture into the reaction cavity. The first and second body portions 20 , 22 , the internal housing 30 , and the header body 32 preferably comprise stainless steel so as to provide for sufficient mechanical integrity for confining the release of energy of the pyrotechnic charge 36 to within the housing, in order to direct the released energy through an exit apperture or outlet 66 , for example via vent tube 46 .
The outlet end of the housing 18 does not disintegrate upon activation of the pyrotechnic, as in the conventional embodiments. Instead, the energy is confined and focused through the exit aperture 66 , or, in the case where the vent tube 46 is employed, through the exit vent 50 and side vents 48 .
A ground pin 24 and first and second contact pins 26 , 28 pass through the first body 20 and through the internal housing 30 and the header body 32 . The contact pins 26 , 28 are coupled to the ground pin 24 via a bridge wire 52 . The pins 24 , 26 , 28 and bridge wire 52 are preferably formed of an electrically conductive material that is resistant to corrosion in adverse environments. The bridge wire 52 is preferably insulated from the body of the inner housing and contacts the pyrotechnic charge 36 . At activation of the pyrotechnic charge 36 , a voltage or current is applied across the ground pin 24 and contact pins 26 , 28 . The bridge wire operates as a fuse that is shorted by the applied voltage or current, which in turn initiates the pyrotechnic.
In a preferred embodiment, the bridge wire 52 comprises redundant first and second bridge wires 52 A and 52 B for improved reliability in the event of failure of one of the bridge wires. The first and second bridge wires 52 A, 52 B may be configured in a cross-pattern as shown in FIG. 4A to more evenly distribute the initial activation of the pyrotechnic charge. Alternatively, the redundant bridge wires may be configured in a parallel arrangement, as shown in FIG. 4 B. In the case of redundant wires, the first and second bridge wires 52 A, 52 B are insulated from each other, and from the header body 32 . One end of each bridge wire 52 A, 52 B is connected to a contact pin and the other end is connected to ground, for example a ground pin. The body of the housing, including the header body 32 , may be grounded. In a preferred embodiment, the bridge wire comprises platinum.
A glass-to-metal seal 34 , for example comprising an epoxy-based thermal plastic elastomer, prevents venting or leakage of the activated pyrotechnic charge gasses from penetrating the rear of the initiator 100 along the bodies of the ground and contact pins 24 , 26 , 28 .
A pyrotechnic charge 36 is located adjacent the header body 32 , in direct contact with the bridge wire 52 . The pyrotechnic charge 36 may comprise cis-bis-(5-nitrotetrazolato)tetraminecobalt(III)perchlorate (BNCP), zirconium potassium perchlorate (ZPP), titanium-hydride-potassium-perchlorate (THPP), or lead azide (PbN 6 ).
BNCP is a preferred pyrotechnic, since it is a relatively insensitive energetic and therefore is conducive to manufacturing and shipping of product. It is more stable, yet provides at least twice the impetus, or ballistic potential, of the other listed pyrotechnics, per unit volume. This is an advantage where size reduction and overall energy content are the focus. BNCP further undergoes a deflagration-to-detonation transition in a much shorter column length relative to the other pyrotechnics, and therefore is amenable to use in smaller devices. In addition, the byproducts of BNCP are also less harmful to the environment, relative to the other listed pyrotechnics.
A retention sleeve 40 , for example formed of nylon, is positioned adjacent the pyrotechnic charge 36 . The sleeve is configured to seat within the second housing body 22 , and to mate with, seams formed in a head portion 58 at a proximal end of vent tube 46 , in order to secure the tube 46 in a lateral direction with respect to the housing 18 .
The vent tube 46 includes a head portion 58 , as described above, a body portion 60 and a neck portion 62 . The head portion is adapted to mate with the retention sleeve 40 , as described above. The body portion 60 is adapted to closely fit within the inner wall of the second housing body 22 . A groove 64 is formed in the outer wall of the body portion 60 , to provide a seat for an O-ring 44 . Details of, and the operation of, the O-ring 44 are described in further detail below.
An exit aperture 66 is formed in an outer wall of the second housing body 22 . The neck portion 62 of the vent tube 46 extends through the exit aperture 66 . An exit seal 68 may be provided between the neck portion 62 and the inner wall of the second housing body 22 to prevent contaminants from interfering with operation of the O-ring 44 .
The vent tube 46 preferably includes a longitudinal primary exit vent 50 for directing the activated pyrotechnic charge 36 to a location external to the initiator 100 . Secondary side vents 48 may optionally be included in the neck portion 62 for providing a more evenly distributed burn of the material to be ignited by the released pyrotechnic charge about the neck. The vent tube 46 is preferably formed of stainless steel.
A tube seal 42 , for example comprising a fluoropolymeric sealant, prevents moisture and other contaminants that migrate down the capillary 38 of the vent tube 46 from entering the reaction chamber of the pyrotechnic charge.
FIG. 2 is a cross-sectional view of the microcapillary initiator of FIG. 1 immediately following activation of the pyrotechnic charge 36 . Current, or voltage, is provided between the ground pin 24 and the first and second contact pins 26 , 28 . This causes a short circuit to occur across the bridge wire 52 , which, in turn, energizes the pyrotechnic charge 36 .
The explosion of the pyrotechnic charge 70 is confined by the walls of the housing 18 and focused through the exit aperture 66 or vent tube 46 . The explosion is accompanied by superheated gases and particulates, which provide for the resulting flame 72 . The released energy causes the nylon retention sleeve 40 and the tube seal 42 to disintegrate. The resulting byproducts are carbon-based and are therefore benign to the generation of the flame 72 .
The superheated gases and particulates are directed down the primary exit vent 50 and through the secondary side vents 48 of the vent tube 46 . In this manner the ignition flame spread 72 is evenly distributed about the vent tube 46 , and fully consumes a material that is exposed to the flame 72 , for example a gel or liquid propellant, to provide a controlled burn of the propellant with high reproducibility and high reliability.
The initiator design of the present invention, including the microcapillary vent tube 46 , provides for accurate and evenly distributed flame/hot particulate in a pulse type pattern. This is a result of the vented primary flash tube 50 , as well as the side vents 48 , which promote such even distribution, as a result of hydrodynamic fluid flow characteristics.
During ignition and burn of the pyrotechnic charge 70 superheated gases are released at a high pressure. The O-ring 44 prevents the gas from escaping from the reaction region, a phenomenon referred to in the art as “blow-by”, which would otherwise reduce the efficiency and reliability of the burn.
In order to prevent or mitigate the occurrence of blow-by, an O-ring 44 is provided in a groove 64 formed in the body portion 60 of the vent tube 46 . With reference to the closeup cross-sectional view of FIG. 3A, the O-ring 44 preferably comprises first, second, and third sub-O-rings 44 A, 44 B, 44 C having minimal to no spacing between each other.
As shown in FIG. 3B, prior to ignition of the pyrotechnic, the first second and third O-rings 44 A, 44 B, 44 C are compressed into the groove 64 formed in the body portion 60 of the vent tube 64 . The O-rings 44 are compressed into the groove 84 between the body portion 60 and the inner wall of the second housing body 22 . In a preferred embodiment, the first and third sub-O-rings 44 A, 44 C comprise Bakelite and the second O-ring 44 B comprises Neoprene.
At ignition of the pyrotechnic charge, pressure is exerted on the O-rings 44 by the superheated, and contained, gases 70 . The applied pressure pushes the O-ring into the gap 72 between the inner wall of the second housing 22 and the body portion 60 of the vent tube, causing the O-ring 44 to obstruct passage of the gas 70 . In this configuration, the exerted pressure 70 is preferably evenly distributed along the side portion of the leftmost O-ring 44 A to cause the O-rings 44 to be thrust forward and outward and into the gap 72 . Otherwise, the pressure may push the O-rings 44 inwardly into the groove 64 , out of the way of the gap 72 , which would result in blow-by of the gas 70 . For this reason, the O-ring groove 64 is preferably wider than the width of the O-ring 44 (or the combined widths of the multiple O-rings 44 A, 44 B, 44 C), as shown in FIG. 3B, in order to allow the pressure to reach the inner portion of the O-ring.
For purposes of the present disclosure, two O-ring designs may be considered, both of which meet the reliability requirements. In a first design, all of the three sub-O-rings 44 A, 44 B, 44 C of the O-Ring 44 do not fail under maximum allowable pressure. In a second design, two of the three sub-O-rings do not fail under the maximum allowable pressure.
Assume the unreliabilities of the three sub-O-rings in terms of heat content to be:
q 1 ( t )=1− e −λ1t (1)
q 2 ( t )=1− e −λ2t (2)
q 3 ( t )=1− e −λ3t (3)
where λ 1 , λ 2 , λ 3 represent the respective failure rates of each sub-O-Ring 44 A, 44 B, 44 C shown in FIG. 3 .
Under the first design, all of the sub-O-rings operate. This is therefore a series system, the reliability G(q(t)) of which is represented by:
G ( q ( t ))=1− e −λ1t e −λ2t e −λ3t
Differentiating with respect to λ 1 , λ 2 , λ 3 respectively yields:
δ G ( q ( t ))/δλ 1 =te −(λ1+λ2+λ3)t (4)
δ G ( q ( t ))/δλ 2 =te −(λ1+λ2+λ3)t (5)
δ G ( q ( t ))/δλ 3 =te −(λ1+λ2+λ3)t (6)
Thus, the Lambert function is used to calculate the ratio or percent reliability of each functioning O-ring in the system:
( I i ) UF ( t )=[λ i te −(λ1+λ2+λ3)t ]/[1− −(λ1+λ2+λ3)t ] (7)
Under the second design, two out of the three sub-O-rings do not fail under maximum pressure. The reliability of this system is represented by:
G ( q ( t ))= q 1 q 2 +q 2 q 3 +q 3 q 1 −2 q 1 q 2 q 3 (8)
or
G ( q ( t ))=1− e −(λ1+λ2)t −e −(λ1+λ3)t −e −(λ1+λ2)t −e −(λ2+λ3)t +2 e −(λ1+λ2+λ3)t (9)
Differentiating with respect to λ 1 , λ 2 , λ 3 respectively yields:
δ G ( q ( t ))/δλ 1 =te −(λ1+λ2)t +te −(λ1+λ3)t −2 te −(λ1+λ2+λ3)t (10)
δ G ( q ( t ))/δλ 2 =te −(λ1+λ2)t +te −(λ2+λ3)t −2 te −(λ1+λ2+λ3)t (11)
δ G ( q ( t ))/δλ 3 =te −(λ1+λ3)t +te −(λ2+λ3)t −2 te −(λ1+λ2+λ3)t (12)
The Lambert function provides:
( I i ) UF ( t )=[λ i /G ( q ( t ))][δ G ( q ( t ))/δλ 1 ] (13)
where i=1, 2, 3
The multiple-O-ring design, and their location within the initiator, therefore provide for increased reliability and a reduction of gas blow-by during activation of the initiator.
In this manner, the present invention provides for a highly reliable pyrotechnic ignition system. The mechanical integrity of the reaction chamber ensures that the energy of the reaction is directed to an outlet of the chamber. A vent tube may be provided at the outlet for further directing the released energy to provide a controlled flame spread that is predictable and repeatable. A redundant bridge wire configuration may be provided for improving system reliability. BNCP is preferably employed as the propellant, taking advantage of its stability, reliability, and high output power. The system is therefore well suited for application to ignition of liquid and gel propellants.
While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made herein without departing from the spirit and scope of the invention as defined by the appended claims | A high-precision pyrotechnic initiator is well adapted for rapid, precise ignition of solid and liquid energetics. A rigid housing, for example formed of stainless steel, contains a pyrotechnic. When ignited, the reaction, or explosion, of the pyrotechnic is confined to the housing. The release of energy creates a hot particulate in which the formation of solid byproducts is mitigated or eliminated. The flame is directed through an outlet. In one embodiment, a microcapillary tube may be placed in communication with the outlet, the tube including a primary front vent and secondary side vents, which serve to increase system efficiency and reliability. A dual bridge wire may be provided for improving system reliability. The resulting assembly thereby performs the combined functions of both an igniter and a flash tube and a complete ignition train is provided in a manner that overcomes the limitations of the conventional configurations. | 5 |
FIELD OF THE INVENTION
One object of the present invention provides an organic-inorganic hybrid film material consisting of polyimide and either poly(silsesquioxane) or silicon alkoxide.
BACKGROUND OF THE INVENTION
Metal material, ceramic material, polymeric material, and electronic material are four main classes in current material science field. Each material owns its specific properties for certain use. For example, the polymeric material has advantages of its readily processing, robustness, resilience, corrosive-resistance, electrical-insulation, and low cost but has disadvantages of poor heat-resistance and mechanical property. The ceramic material has advantages of stiffness, low activity, thermal stability but has disadvantages of heavy and brittleness. It will develop a new material having new properties if someone takes advantages of one material for compensating shortcoming of another material. Such a concept attracts people's attention to further investigate an organic-inorganic material hybrid material.
Conventional composite has a domain in the order of microns to millimeters. In such a composite the organic or inorganic component mainly plays a role for varying a structure or function of the composite. Its preparation mainly comprises a physical blending. Additionally, the hybrid material is prepared by sol-gel or self-assembly process to hybridize the organic and inorganic material. For example, incorporation of organic material into inorganic master material will improve the inorganic material's brittleness and could render the inorganic material colors. Alternatively, incorporation of inorganic material into organic master material will improve the organic material's strength, heat-resistance and hygroscopicity. Thus, new material having novel properties will be developed through molecular design.
Conventional organic-inorganic material should always be heated at elevated temperature to achieve its complete cross-linking and remove moisture or solvent contained in the reaction system. Silica/polyimide hybrid material prepared from sol-gel process has been extensively investigated due to its excellent heat-resistance. Such a heat-resistance is useful especially in the IC production requiring to process at an elevated temperature. One process for producing the silica/polyimide hybrid material comprises the steps of physically mixing poly(amic acid) solution with tetraethyl orthosilicate (TEOS) solution, spin-coating and then heated and cured to form a film. However, a phase separation will occur in the reaction system. To avoid the phase separation, an approach is to introduce coupling agent into the system since coupling agent will provide a bonding between two immiscible materials. Analysis to the silica/polyimide hybrid material resides in its optical property, a ratio of the organic to inorganic material, and hygroscopicity. There are many kinds of silica/polyimide hybrid material including water-soluble hybrid material, stiff hybrid material, and photo sensitive hybrid material, each of which has different use.
Increasing with the maturation for developing the silica/polyimide hybrid material, more research to the silicon-based material has been conducted. Among them, poly(silsequioxane) has been attracted due to its low dielectric index. With decreasing of line width on integrated circuit board, there exists a problem of signal transmission delay. To decrease the effect of signal delay [Resistance Capacitor (RC) delay], one method is to decrease resistance by using copper process and another method is to decrease capacitor formed between two conductive lines by using insulator layer having low dielectric index. Thus, development of material having low dielectric index becomes a major subject in material science field recently. Among them, poly(silsesquioxane) has a dielectric index of from 2.6 to 2.9, which is far less than that of silica (i.e. dielectric index of 4.0).
Generally, poly(silsesquioxane) is prepared from a hydrolysis of trifunctional silane monomer and then condensation in which the functional groups are the same or different and selected from chloro, methoxy, or ethoxy. Molecular weight, structure of the condensing product and the number of terminal functional groups present in the condensing product are greatly affected by reaction conditions such as properties of monomer, reaction temperature, kinds of catalyst and solvents. Among poly(silsesquioxane), poly(methyl silsesquioxane)(PMSQ) is most popular and becomes an excellent low dielectric material since it has a dielectric index of 2.7, low hygroscopicity, excellent heat-resistance, and mechanical strength. However, PMSQ exhibits poor adhesion to silicon wafer and is brittle thus its use is limited. Introduction of organic polymer into PMSQ will overcome such disadvantages.
Using poly(silsesquioxane)/polyimide hybrid material to prepare low dielectric film is known. It is now describing as follows.
(1) Diamine is first reacted with dianhydride to form poly(amic acid). Then methyl trimethoxy silane monomer (MTMS, a starting monomer for poly(silsesquioxane)) and coupling agent are added into the poly(amic acid) solution to allow the MTMS hydrolyzing and condensing catalytically by using acidic property of the poly(amic acid). Finally, the resultant solution is coated on a substrate and cured to form a film. In this method, although addition of coupling agent provides a bonding between inorganic material and organic material, there still exists a problem of phase separation. This is because that it is difficult to control the MTMS reaction condition precisely, thus it is difficult to control the content of Si—OH and then results in poor property of the film due to phase separation. Moreover, a byproduct methanol still remains in the reaction system. (2) Poly(silsesquioxane) and poly(amic acid alkyl ester) are prepared separately, and then mixed with addition of coupling agent to subject to a hybridization. Finally, the resultant hybrid material solution is coated on a substrate and cured to form a film. In this method, poly(amic acid alkyl ester) is used the precursor for polyimide, other than poly(amic acid). By using poly(amic acid alkyl ester) as the precursor for polyimide, it can be dissolved in more kinds of solvents but it also limits the ratio of organic material to inorganic material. For example, in such method, proportion of the polyimide is at most of 30% and thus it is impossible to use polyimide as a master material to produce a hybrid material.
Summary, preparation of low dielectric film and optical waveguide material from poly(silsesquioxane)/polyimide hybrid material has the following questions: (1) evenly dispensing of the organic into inorganic materials is difficult and thus easily results in phase separation; (2) only one of organic material and inorganic material could be used as a master material due to the limited ratio of the organic material to inorganic material.
To overcome the disadvantages of the conventional organic-inorganic material, the present inventors have investigated a process for producing a hybrid material and thus completed the present invention.
SUMMARY OF THE INVENTION
One object of the present invention provides an organic-inorganic hybrid film material consisting of polyimide and either poly(silsesquioxane) or silicon alkoxide.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a reaction scheme for the process for preparing an organic-inorganic hybrid film material according to the present invention from poly(amic acid) and poly(silsesquioxane);
FIG. 2 shows a FT-IR spectrum of the organic-inorganic hybrid film prepared from Examples 2 to 8;
FIG. 3 shows a AFM(Atomic Force Microscopic) spectrum of an organic-inorganic hybrid film prepared from 60% by weight of poly(methyl-silsesquioxane) and 40% by weight of poly(amic acid);
FIG. 4 shows a plot of roughness of the hybrid film vs. content of poly(methyl-silsesquioxane);
FIG. 5 shows surface and cross-section SEM graph of the organic-inorganic hybrid film prepared by the process according to the present invention;
FIG. 6 shows a plot graph of refractive index of the hybrid film vs. the content of poly(methyl-silsesquioxane) at different wavelength;
FIG. 7 shows a plot graph of birefractive index of the hybrid film vs. the content of poly(methyl-silsesquioxane) at different wavelength;
FIG. 8 shows a near-IR absorption spectrum of the organic-inorganic hybrid film prepared by the process according to the present invention;
FIG. 9 shows a plot graph of dielectric index of the hybrid film vs. the content of poly(methyl-silsesquioxane);
FIG. 10 shows a TGA graph of the organic-inorganic hybrid film prepared by the process according to the present invention;
FIG. 11 shows a plot graph of pyrolysis temperature of the hybrid film vs. the content of poly(methyl-silsesquioxane); and
FIG. 12 shows a thermo-stress graph of the organic-inorganic hybrid film prepared by the process according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a process for preparing an organic-inorganic hybrid film material, which comprises the steps of:
(a) reacting an aromatic diamine with aromatic dianhydride at a temperature of from room temperature to 50° C. to give poly(amic acid), in which an equivalent ratio of the aromatic diamine to the aromatic dianhydride is less than 2; (b) coupling the poly(amic acid) from step (a) with an amino coupling agent having a general formula of NH 2 —R 1 —Si(R 2 ) 3 in which R 1 s a C 1-6 alkylene or phenylene group, R 2 s are the same or different and represent C 1-6 alkoxy group, to give a poly(amic acid) terminated with the amino coupling agent, in which the equivalent of the added coupling agent is less than that of the diamine; (c) subjecting a monomer of formula R 3 —Si(R 4 ) 3 (wherein R 3 represents a hydrogen, C 1-6 alkyl, C 2-6 alkenyl, and phenyl, and R 4 s are the same or different and represent a halogen, C 1-6 alkoxy, C 2-6 alkenyloxy, and phenoxy group) to sol-gel reaction in the presence of acidic catalyst in a solvent at a temperature of from room temperature to 100° C., to give poly(silsesquioxane); wherein the acidic catalyst is added in an amount sufficient to maintain a pH of the reaction mixture at a range from 1 to 4; (d) hydrolyzing the poly(amic acid) terminated with the amino coupling agent from step (b) in the presence of deionized water and then coupling with the poly(silsesquioxane) from step (c), to give a slurry of poly(amic acid)-poly(silsesquioxane) composite material; wherein the amount of deionized water for hydrolyzing the amino coupling agent which is coupled to the poly(amic acid) is molar equivalent to or slight excess the moles of terminal alkoxy group present in the poly(amic acid) terminated with the amino coupling agent; (e) applying the resultant composite material slurry on a substrate, curing the coated slurry at an elevated temperature to produce an organic-inorganic hybrid film material of polyimide/poly(silsesquioxane).
The present invention also relates to a process for preparing an organic-inorganic hybrid film material, which comprises the steps of:
(a1) reacting an aromatic diamine with aromatic dianhydride at a temperature of from room temperature to 50° C. to give poly(amic acid), in which an equivalent ratio of the aromatic diamine to the aromatic dianhydride is less than 2; (b1) coupling the poly(amic acid) from step (a1) with an amino coupling agent having a general formula of NH 2 —R 1 —Si(R 2 ) 3 in which R 1 is a C 1-6 alkylene or phenylene group, R 2 s are the same or different and represent C 1-6 alkoxy group, to give a poly(amic acid) terminated with the amino coupling agent, in which the equivalent of the added amino coupling agent is less than that of the diamine; (d1) hydrolyzing the poly(amic acid) terminated with the amino coupling agent from step (b1) in the presence of deionized water and then coupling with silicon alkoxide, to give a slurry of poly(amic acid)-silicon alkoxide composite material; wherein the amount of deionized water for hydrolyzing the amino coupling agent which is coupled to the poly(amic acid) is molar equivalent to or slight excess the moles of terminal alkoxy group present in the poly(amic acid) terminated with the amino coupling agent; (e1) applying the resultant composite material slurry on a substrate, curing the coated slurry at an elevated temperature to produce an organic-inorganic hybrid film material of polyimide/silicon alkoxide.
The process according to the present invention is illustrated more detail by reference to the reaction scheme shown in FIG. 1 .
The term “poly(amic acid)” used herein refers to a product containing a functional groups of —NH—CO— and —COOH which are generated by reacting the diamine and the dianhydride.
The term “polyimide” used herein refers to a product obtained from curing the poly(amic acid) as defined above at an elevated temperature then cyclizing the functional group —NH—CO— with a carboxylic functional group contained in the poly(amic acid). Accordingly, the product from reacting the diamine and the dianhydride refers to “poly(amic acid)” before curing and it refers to “polyimide” after curing.
The term “C 1-6 alkyl group” used herein refers to a straight or branched chain alkyl group containing 1 to 6 carbon atoms, such as methyl, ethyl, n-propyl, isopropyl, n-butyl, s-butyl, t-butyl, n-pentyl, neopentyl, hexyl, and the like.
The term “C 2-6 alkenyl group” used herein refers to a straight or branched chain hydrocarbyl group containing 2 to 6 carbon atom and at least one carbon-carbon double bond, such as vinyl, allyl, propenyl, butenyl, pentenyl, and hexenyl, and the like.
The term “halogen” used herein refers to fluorine, chlorine, bromine, and iodide atom, preferably iodine atom.
The term “C 2-6 alkoxy group” used herein refers to the alkyl group defined as above connected via an oxygen atom, such as methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, s-butoxy, t-butoxy, n-pentoxy, neopentoxy, hexoxy, and the like.
The term “C 2-6 alkenyl group” used herein refers to a straight or branched chain hydrocarbyl group containing 2 to 6 carbon atom and at least one carbon-carbon double bond, such as vinyl, allyl, propenyl, butenyl, pentenyl, and hexenyl, and the like.
The term “C 2-6 alkenyloxy group” used herein refers to the alkenyl group as defined above connected via an oxygen atom, such as vinyloxy, allyloxy, propenoxy, butenoxy, pentenoxy, and hexenoxy, and the like.
In the process for producing organic-inorganic hybrid film material according to the present invention, examples of the used aromatic dianhydride include, but not limit to, pyromellitic dianhydride (PMDA), 4,4-biphthalic dianhydride (BPDA), 4,4′-hexa-fluoroisopropylidene-diphthalic dianhydride (6FDA), 1-(trifluoromethyl)-2,3,5,6-benzenetetracarboxylic dianhydride (P3FDA), 1,4-di(trifluoromethyl)-2,3,5,6-benzenetetracarboxylic dianhydride (P6GDA), 1-(3′,4′-dicarboxy-phenyl)-1,3,3-tri-methyl-indan-5,6-dicarboxylic dianhydride, 1-(3′,4′-dicarboxy-phenyl)-1,3,3-trimethyl-indan-6,7-dicarboxylic dianhydride, 1-(3′,4′-dicarboxy-phenyl)-3-methyl-indan-5,6-dicarboxylic dianhydride, 1-(3′,4′-dicarboxy-phenyl)-3-methyl-indan-6,7-dicarboxylic dianhydride, 2,3,9,10-perylene-tetracarboxylic dianhydride, 1,4,5,8-naphthalene-tetracarboxylic dianhydride, 2,6-dichloro-naphthalene-1,4,5,8-tetracarboxylic dianhydride, 2,7-dichloro-naphthalene-1,4,5,8-tetracarboxylic dianhydride, 2,3,6,7-tetrachloro-naphthalene-2,4,5,8-tetracarboxylic dianhydride, phenanthrenc-1,8,9,10-tetracarboxylic dianhydride, 3,3′,4′4′-benzophenone-tetracarboxylic dianhydride, 2,2′,3,3′-benzophenone-tetracarboxylic dianhydride, 3,3′,4′,4′-biphenyl-tetracarboxylic dianhydride, 2,2′,3,3′-biphenyl-tetracarboxylic dianhydride, 4,4′-isopropylidene-diphthalic anhydride, 3,3′-isopropylidene-diphthalic anhydride, 4,4′-oxy-diphthalic anhydride, 4,4′-sulfonyl-diphthalic anhydride, 3,3′-oxy-diphthalic anhydride, 4,4′-methylene-diphthalic anhydride, 4,4′-thio-diphthalic anhydride, 4,4′-ethylidene-diphthalic anhydride, 2,3,6,7-naphthalene-tetracarboxylic dianhydride, 1,2,4,5-naphthalene-tetracarboxylic dianhydride, 1,2,5,6-naphthalene-tetracarboxylic dianhydride, benzene-1,2,3,4-tetracarboxylic dianhydride, pyrazine-2,3,5,6-tetracarboxylic dianhydride, and a combination thereof. Among, pyromellitic dianhydride (PMDA), 4,4-biphthalic dianhydride (BPDA), 4,4′-hexafluoroisopropylidene-diphthalic dianhydride (6FDA), 1-(trifluoromethyl)-2,3,5,6-benzenetetracarboxylic dianhydride (P3FDA), 1,4-bis(trifluoromethyl)-2,3,5,6-benzenetetracarboxylic dianhydride (P6GDA) are preferable.
In the process for producing organic-inorganic hybrid film material according to the present invention, examples of the used aromatic diamine include, but not limit to, 4,4′-oxy-dianiline (ODA), 5-amino-1-(4′-aminophniyl)-1,3,3-trimethyl-indane; 6-amino-1-(4′-aminophenyl)-1,3,3-trimethyl-indane, 4,4′-methylene-bis(o-chloro-aniline), 3,3′-dichloro-dibenzidme, 3,3′-sulfonyl-dianiline, 4,4′-diamino-benzophenone, 1,5-diamino-naphthalene, bis(4-aminophenyl)diethyl silane, bis(4-aminophenyl)diphenyl silane, bis(4-aminophenyl)ethyl phosphine oxide, N-[bis(4-aminophenyl)]-N-methyl amine, N-(bis(4-aminophenyl))N-phenyl amine, 4,4′-methylene-bis(2-methyl-aniline), 4,4′-methylene-bis(2-methoxy-aniline), 5,5′-methylene-bis(2-aminophenol), 4,4′-methylene-bis(2-methyl-aniline), 4,4′-oxy-bis(2-methoxy-aniline), 4,4′-oxy-bis(2-cliloro-aniline), 2,2′-bis(4-aminophenol), 5,5′-oxy-bis(2-aminophenol), 4,4-thio-bis(2-methyl-aniime), 4,4′-thio-bis(2-methoxy-aniline), 4,4′-thio-bis(2-chloro-aniline), 4,4′-sulfonyl-bis(2-methyl-aniline), 4,4′-sulfonyl-bis(2-ethoxy-aniline), 4,4′-sulfonyl-bis(2-chloro-aniline), 5,5′-sulfonyl-bis(2-aminophenol), 3,3′-dimethyl-4,4′-diamino-benzophenone, 3,3′-dimethoxy-4,4′-diamino-benzophenone, 3,3′-dichloro-4,4′-diamino-benzophenone, 4,4′-diamino-biphenyl, m-phenylenediamine, p-phenylene-diamine, 4,4′-methylene-dianiline, 4,4′-thio-dianiline, 4,4′-sulfonyl-dianiline, 4,4′-isopropylidene-dianiline, 3,3′-dimethyl-dibenzidine, 3,3′-dimethoxy-dibenzidine, 3,3′-dicarboxy-dibenzidine, 2,4-tolyl-diamine, 2,5-tolyl-diamine, 2,6-tolyl-diamine, m-xylyl-diamine, 2,4-diamino-5-chloro-toluene, 2,4-diamino-6-chloro-toluene, and a combination thereof. Among them, 4,4′-oxy-dianiline (ODA) is preferable.
In the process for producing organic-inorganic hybrid film material according to the present invention, examples of the used silicon alkoxide include, but not limit to, tetramethoxysilane, tetraethoxysilane, and the like.
In the process for producing organic-inorganic hybrid film material according to the present invention, the reactions in steps (a) and (a1) are preferably carried out in a solvent. The solvent can be any kind of solvent as long as it is inert to the reaction. Examples of the solvent include, but not limit to, N,N-dimethylacetamide (DMAc), 1-methylpyrrolidone (NMP), N,N-dimethylformamide (DMF), tetrahydrofuran (THF), dioxane, methyl ethyl ketone (MEK), chloroform, methylene chloride, and the like.
In the process for producing organic-inorganic hybrid film material according to the present invention, examples of the amino coupling agent of formula NH 2 —R 1 —Si(R 2 ) 3 used in steps (b) and (b1) include, but not limit to, 3-aminopropyl trimethoxy silane (APrTMS), 3-aminopropyl triethyl silane (APrTES), 3-aminophenyl trimethoxy silane (APTMS), 3-aminophenyl triethoxy silane (APTES), and the like.
In the process for producing organic-inorganic hybrid film material according to the present invention, examples of monomer of formula R 3 —Si(R 4 ) 3 used in step (s) for preparing poly(silsesquioxane) include, but not limit to, methyl trimethoxy silane (MTMS), trimethoxy silane (TMS), triethoxy silane (TES), methyl triethoxy silane (MTES), phenyl trimethoxy silane (PTMS), phenyl triethoxy silane (PTES), vinyl trimethoxy silane (VTMS), vinyl triethoxy silane (VTES), trichlorosilane, methyl trichloro silane, phenyl trichloro silane, vinyl trichloro silane, and the like.
The catalyst used in step (c) of the process of the present invention can use organic acid and inorganic acid. Examples of the organic acid include, but not limit to, hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, and the like. Examples of the inorganic acid include, but not limit to, formic acid, acetic acid, propionic acid, oxalic acid, malonic acid, succinic acid, glutaric acid, glycolic acid, tartaric acid, and the like.
The solvent used in step (c) of the process of the present invention can use any kind of solvent as long as it is inert to the reaction. Examples of the solvent include, but not limit to, N,N-dimethylacetamide (DMAc), 1-methylpyrrolidone (NMP), N,N-dimethylformamide (DMF), tetrahydrofuran (THF), dioxane, methyl ethyl ketone (MEK), chloroform, methylene chloride, and the like. Among them, N,N-dimethylacetamide (DMAc) is preferable.
The process for producing organic-inorganic hybrid film material according to the present invention further comprises a step of distillating the poly(silsesquioxane) at reduced pressure to remove byproduct methanol after step (c). The distillation is preferably carried out at a temperature of from 40 to 45° C. If the distillation temperature is too high, the reaction will be continued. If the temperature is too low, it is insufficient to distillate methanol off thoroughly. After the distillation step, the solvent used in the reaction can be further added into the distillated mixture to adjust its solid content to from 10 to 20% by weight.
After the step (c), if the byproduct methanol is not distillated off, the poly(silsesquioxane) should be used in an amount of only up to 30% by weight, otherwise the poly(amic acid) will precipitate out.
In the steps (d) and (d1) of the process according to the present invention, the poly(silsesquioxane) or the silicon alkoxide can be mixed with the poly(amic acid) in any ratio. All ratios will not cause the mixture precipitation or turbidity.
In the steps (e) and (e1) of the process according to the present invention, applying the composite material slurry on a substrate can be conducted by any coating method well known in this art, including rolling coating method, flow coating method, dip coating method, spray coating method, spin coating method, curtain coating method, and the like. For obtaining an even film, the spin coating method is preferable.
In the steps (e) and (e1) of the process according to the present invention, curing the coated slurry at an elevated temperature is conveniently conducted by a baking method, preferably by a multi-stage baking method at a gradient elevated temperature. By the multi-stage baking method, the solvent contained in the coated slurry will be evaporated slowly to avoid the crack of a film. The multi-stage baking method includes, but not limit to, baking the coated slurry at a temperature of 50 to 70° C. for 15 to 25 minutes form a film, then baking the film at a temperature of 90 to 110° C. for 15 to 25 minutes, then baking it at a temperature of 140 to 160° C. for 15 to 25 minutes, then curing it in an oven at a temperature of 290 to 310° C. under a nitrogen atmosphere for several hours, and finally curing it at a temperature of 390 to 420° C. for several hours.
The present invention will be illustrated by reference to the following examples. However, the examples are only for illustration purpose without limiting the scope of the present invention.
EXAMPLE 1
Preparation of poly(amic) having a theoretical molecular weight of 5000 gram/mole. 0.686 Grams of 4,4′-oxy-dianiline (ODA) were dissolved in 8.5 g of N,N-dimethylacetamide (DMAc) and stirred for 20 minutes. Then 0.814 g of pyromellitic dianhydride (PMDA) were added slowly and stirred for 4 hours at room temperature. Then 0.107 g of 3-aminopropyl trimethoxy silane (APrTMS) were added. A mole ratio of PMDA:ODA:APrTMS was 12.4:11.4:2. After the addition of APrTMS, the reaction was carried out for further 20 minutes to obtain poly(amic acid) solution (A).
Preparation of poly(methyl-silsesquioxane) solution. A three-neck bottle equipped with a condensor and a nitrogen inlet was charged with 10.17 g of methyl trimethoxy silane (MTMS) monomer, then charged with 30 g of N,N-dimethyl-acetamide (DMAc). The mixture was heated reflux in a silicone oil bath under nitrogen atmosphere. Separately, 7.14 g of DMAc, 2.687 g of deionized water, and 0.055 g of 35% aqueous hydrochloric acid solution were charged into a funnel at a constant pressure. The mixture was added dropwise into the above three-neck bottle over 30 minutes. The reaction was continued for 3 hours. The resultant solution was concentrated by a rotary evaporator at a temperature of 40° C. in vacuum to remove byproduct methanol and part of used solvent to obtain a mixture having a solid content of 30%. Then the solid content of the mixture was adjusted to 15% by adding DMAc to obtain poly(methyl-silsesquioxane) solution (C).
Sol-gel reaction of poly(methyl-silsesquioxane) solution and poly(amic acid). Into a mixture of 1 g of poly(methyl-silsesquioxane) solution (C) and 9 g of poly(amic acid) (A) was added 0.039 g of deionized water and the mixture was stirred at room temperature for 1 hour to hydrolyze the terminal alkoxysilyl group contained in the poly(amic acid). It resulted a hybrid solution of poly(methyl-silsesquioxane)-poly(amic acid) in which the amount of poly(methyl-silsesquioxane) is 10% by weight base on the total weight of poly(methyl-silsesquioxane) and poly(amic acid).
The resultant hybrid solution was spin coated on a 4″ silicon wafer at 3000 rpm for 60 seconds to form a film, then baked it on a hot plate on the following schedule: 60° C. for 20 minutes, 100° C. for 20 minutes, 150° C. for 20 minutes. Then the baked film was transferred into an oven at a temperature of 300° C. under a nitrogen atmosphere then cured for 1 hour. Finally, the film was further cured in the oven for 1 hour by increasing the temperature from 300° C. to 400° C. to obtained a poly(methyl-silsesquioxane)-polyimide hybrid film.
EXAMPLES 2 TO 8
Examples 2 to 8 followed the procedures as mentioned in Example 1 except the weight ratio of the poly(methyl-silsesquioxane) was changed to 0%, 20%, 40%, 60%, 80%, 100%, and 100%, respectively. Also, the film obtained from Example 8 was only subjected to baking on hot plate without curing in oven.
EXAMPLE 9
Preparation of poly(amic) having a theoretical molecular weight of 1000 gram/mole. 0.569 Grams of 4,4′-oxy-dianiline (ODA) were dissolved in 8.5 g of N,N-dimethulacetamide (DMAc) and stirred for 20 minutes. Then 0I931 g of pryomellitic dianhydride (PMDA) were added slowly and stirred for 4 hours at room temperature. Then 0.509 g of 3-aminopropyl trimethoxy silane (APrTMS) were added. A mole ratio of PMDA:ODA:APrTMS was 3:2:2. After addition of APrTMS, the reaction was carried out for further 20 minutes to obtain poly(amic acid) solution (B).
The resultant hybrid solution was spin coated on a 4″ silicon wafer at 3000 rpm for 60 seconds to form a film, then baked it on a hot plate on the following schedule: 60° C. for 20 minutes, 100° C. for 20 minutes, 150° C. for 20 minutes. Then the baked film was transferred into an oven at a temperature of 300° C. under a nitrogen atmosphere then cured for 1 hour. Finally, the film was further cured in the oven for 1 hour by increasing the temperature from 300° C. to 400° C. to obtained a poly(methyl-silsesquioxane)-polyimide hybrid film.
EXAMPLE 10
Preparation of poly(amic) having a theoretical molecular weight of 1000 gram/mole. 4.10 Grams of 4,4′-oxy-dianiline (ODA) were dissolved in 62.2 g of N,N-dimethylacetamide (DMAc) and stirred for 20 minutes. Then 9.12 g of 4,4-biphthalic dianhydride (BPDA) were added slowly and stirred for 4 hours at room temperature. Then 3.68 g of 3-aminopropyl trimethoxy silane (APrTMS) were added. A mole ratio of BPDA:ODA:APrTMS was 3:2:2. After addition of APrTMS, the reaction was carried out for further 20 minutes to obtain a solution (D) of 13.6 g of poly(amic acid) in 62.2 g of N,N-dimethylacetamide.
Sol-gel reaction of silicon alkoxide solution and poly(amic acid). Into the solution (D) of 13.6 g of poly(amic acid) in 62.2 g of N,N-dimethylacetamide was added 15.5 g of tetramethoxysilane (TMOS) and then added 8.3 g of deionized water and the mixture was stirred at room temperature for 1 hour to hydrolyze the terminal alkoxysilyl group contained in the poly(amic acid). It resulted in a solution of silicon alkoxide-poly(amic acid) hybrid material.
The resultant hybrid solution was spin coated on a 4″ silicon wafer at 3000 rpm for 60 seconds to form a film, then baked it on a hot plate on the following schedule: 60° C. for 20 minutes, 100° C. for. 20 minutes, 150° C. for 20 minutes. Then the baked film was transferred into an oven at a temperature of 300° C. under a nitrogen atmosphere then cured for 1 hour. Finally, the film was further cured in the oven for 1 hour by increasing the temperature from 300° C. to 400° C. to obtained a silicon alkoxide-polyimide hybrid film.
The film material obtained from Examples 1 to 10 were analyzed their properties. For example, their FT-IR spectrum, AFM (Atomic Force Microscopic) spectrum, SEM, roughness, refractive index, birefractive index, near-IR spectrum, dielectric constant, TGA spectrum, pyrolysis temperature, and thermeanalysis are shown in FIGS. 2 to 12 , respectively.
From the FT-IR spectrum shown in FIG. 2 , it is found that poly(methyl-silsesquioxane) or silicon alkoxide has been completely reacted, and each peak area varies with its content. From the AFM spectrum shown in FIG. 3 , it is found that polyimide having lower molecular weight has a better surface flatness, in which FIG. 3( a ) shows a poly(amic acid) having molecular weight of 1000, FIG. 3(B) shows a poly(amic acid) having molecular weight of 5000, FIG. 3( c )) shows a poly(amic acid) having molecular weight of 1000 without addition of coupling agent. FIG. 4 shows a plot of roughness of films vs. poly(methyl-silsesquioxane) content. From FIG. 4 , it is know that hybrid film obtained from poly(amic acid) having lower molecular weight has an average roughness of less than 1 nm, and the film obtained without using coupling agent exhibits the largest roughness. From SEM spectrum shown in FIG. 5 , it is known that a hybrid film prepared from poly(amic acid) having higher molecular weight significantly occurs phase-separation in case of reacting with high content of poly(silsesquioxane). It demonstrates that increasing of crosslinking density actually decreases the phase-separation. From FIG. 6 , it is shown that the refractive index can be controlled by changing the weight ratio of poly(amic acid) to poly(silsesquioxane). From FIG. 7 , it is shown that bi-refractive index will be decreased since addition of inorganic material destroys the arrangement of high molecular. Thus, bi-refractive index decreases slightly with the increase amount of inorganic material. FIG. 8 shows a near IR spectrum of the hybrid film of the present invention. The hybrid film of the present invention shows no absorbance in a frequence range use din ooptical waveguide and is useful as optical waveguide material. From FIG. 9 , it is shown that a plot of dielectric index vs. content of poly(methyl-silsesquioxane) of the hybrid film is non-linear graph due to its hygroscopic property and film thickness and the dielectric index decreases with increase of inorganic material. From FIG. 10 , it is shown that addition of inorganic material will increase the heat-resistance of the hybrid film, and the film prepared from poly(amic acid) having higher molecular weight exhibits better heat-resistance than that prepared from poly(amic acid) having lower molecular weight. From FIG. 11 , it is shown that all hybrid films of the present invention have a pyrolysis temperature of more than 545° C. It demonstrates that the hybrid film of the present invention possesses excellent heat-resistance. Also, a DSC analysis for the hybrid film of the present invention shows no glass transition temperature. Finally, from FIG. 12 , it is shown that addition of inorganic material will increase stability of the hybrid film. | The present invention relates to an organic-inorganic hybrid film material consisting of polyamide and either polysilsesquioxane or silicon alkoxide and to a process for producing the organic-inorganic hybrid film material. The present process can effectively reduce the phase separation and can produce an organic-inorganic hybrid film material having 0–100% organic content. The present process can control desired properties of the resultant hybrid film material by adjusting the ratio of the organic and inorganic material, such as refractive index, birefractive index, dielectric index, and plateness of the film. Also, the present organic-inorganic hybrid film material possesses excellent heat-resistivity and is suitable for an IC process requiring high processing temperature. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to a device for attaching the electronic circuit plate of a computer-operated sewing machine.
In conventional computer-operated sewing machines, it has been the real situation that a machine frame having an arm and a bed, an operation panel, an electronic circuit plate, etc. are designed for each model. Accordingly, machine frames, operation panels, electronic circuit plates, etc. of different specifications must be prepared for respective models.
As an improvement, it has been proposed that a modified operation panel and modified electronic circuit plate constructed as a unit be mounted on the machine frame of a certain sewing machine, thereby to change the model of the sewing machine. In actuality, however, standard machine frames are used in a manufacturing plant, and hence, an assembly worker might mistake the modified operation panel unit prepared for each model and assemble a different unit.
The conventional method of production wherein the machine frames, the operation panels, the electronic circuit plates, etc. are prepared for the respective models, has the disadvantage that the sewing machines become costly. On the other hand, the method employing the operation panel units prepared for the respective models has the disadvantage that the sewing machines might be assembled erroneously.
SUMMARY OF THE INVENTION
An object of the present invention is to eliminate the aforementioned disadvantages of the known methods.
The present invention consists in that the machine frames of sewing machines of different models are made standard, thereby to curtail the casting cost, machining cost and assembling cost of the sewing machines, and that a circuit plate-attaching device having coded keying means is provided, thereby to prevent the occurrence of the mistaken assemblage of an operation panel unit of an incorrect model due to the misunderstanding of an assembly worker in handling.
More specifically, in assembling operation panels of the different models in the case where the machine frames are made common for the multifarious sewing machines of the different models, if a drive control circuit plate mounted earlier and the operation panel to be mounted later agree with the desired model, they are smoothly assembled by using the coded keying means which include positioned pins and holes provided between the plate and the panel, whereas if they disagree with the correct model, the assemblage is hindered by the keying means. It is therefore possible to prevent the assemblage of the components of incorrect types due to the mistake of the worker.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings illustrate an embodiment of the present invention, wherein:
FIG. 1 is an exterior view of a sewing machine to which the present invention is applied;
FIG. 2 is a sectional side view of an embodiment of an attachment device showing the essential features of the present invention; and
FIG. 3 is a circuit diagram for elucidating the embodiment electronic control circuits in a sewing machine of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the present invention will be described with reference to the drawings. Numeral 1 indicates a machine frame, in which an arm frame and a bed frame are united. A needle bar 2 is supported by the arm frame so as to be capable of reciprocal movements in the vertical direction and swing movements in the horizontal direction, and it has a needle 3 set at its lower end. A presser bar 4 is supported by the arm frame so as to be vertically slidable, and a presser foot 5 for pressing fabric is mounted on the lower end of the presser bar 4. Shown at numeral 6 is a loop taker of horizontal full rotation which is rotatably supported by the bed frame. A hook (not shown) is formed at a suitable outer-peripheral part of the loop taker 6, and a bobbin (not shown) around which a lower thread is wound is installed inside the loop taker 6. This loop taker 6 is rotated in synchronism with the vertical movements of the needle bar 2 so as to take an upper thread held by the needle 3, whereby the upper thread is interlinked with the lower thread included in the loop taker 6. A first stepping motor 7 serves to control the amplitude of the movements of the needle bar 2, while a second stepping motor 8 serves to control the movement of a feed dog (not shown) for fabric feed. Numeral 9 denotes an operating keyboard, which holds a pattern indication circuit plate 10 therein. The operating keyboard 9 is supported so as to be fitted in the recess of an operation panel 11, thereby to be mounted on the front face of the machine frame 1.
A structure for supporting and attaching the operating keyboard 9 on the operation panel 11, includes a first code set consisting of a pin 12 projecting from the keyboard 9 and a hole 13 formed in the operation panel 11. The pin and the hole are positioned for each model such as to snugly fit in with one another, while bolts (not shown) attached to in the operating keyboard 9 are inserted through corresponding holes of the operation panel 11 and secured by nuts (not shown) so as to fasten the two components 9 and 11 together. In addition the operation panel 11 is mounted on the machine frame 1. In this regard, a second code set consisting of a pin 14 formed on the operation panel 11 and a hole 15 formed in the machine frame 1, are positioned for each model such as to snugly fit in with one another, while screws 16, 16 are tightened to fix the two components 11 and 1. Numeral 17 denotes a CPU (central processing unit) circuit plate which is principally composed of control circuits for controlling the stepping motors 7 and 8. The CPU circuit plate 17 is screwed to the back of the operation panel 11, and is electrically connected with the pattern indication circuit plate 10 (FIG. 3) of the operating keyboard 9 by a connector 18.
Numeral 19 designates a control circuit plate for a drive motor 20 which is supported in the machine frame 1. The drive motor control circuit plate 19 is held in a circuit plate case 22 which is fixed to the machine frame 1 by screws 21, 21. This circuit plate case is made up of a case body 23 and a case cover 24, and along with the case cover 24, the drive motor control circuit plate 19 is fixed to the case body 23 by screws 25, 25. The drive motor control circuit plate 19 and the CPU circuit plate 17 are electrically connected by a connector 26.
Numeral 27 designates a Z-shaped spacing member which at its lower part is screwed to the rear surface of the CPU circuit plate 17, and at its upper part which is opposed to the surface of the cover 24 of the circuit plate case 22 extends in parallel therewith. A third code set consisting of a pin 28 projecting from the case cover 24 and a hole 29 formed in the upper part of spacing member 27 are positioned for each model such as to snugly fit in with one another.
Since the attaching device according to the present invention is constructed with the code sets as described above, it is possible that the machine frames 1 are made common for various machine types of different models, while the specifications of the operating keyboards 9 are changed for the respective models. In this example, the drive motor control circuit plate 19 and the operation panel 11 to be combined for each model are assembled to the machine frame in the order mentioned. Consequently, even when an assembly worker tries to assemble the operation panel 11 of an incorrect model to the drive motor control circuit plate 19 having been assembled to the machine frame 1 earlier, the third code set which consists of the pin 28 and the hole 29 provided between the operation panel 11 and the circuit plate case cover 24 and positioned for each model and the second code set which consists of the pin 14 and the hole 15 provided between the machine frame 1 and the operation panel 11 and positioned for each model, do not come into coincidence, that is, the pins and the holes are not snugly fitted. Therefore, the assembly worker fails to mount the operation panel 11 and immediately notices the mistaken assemblage. It is accordingly prevented to erroneously assemble the operation panel 11 of the incorrect model.
As described above, by virtue of the coded keying means according to the present invention, the mistaken assemblage of erroneous components can be prevented from occurring in a workshop for assembling various types of computer-operated sewing machines, which feature is very greatly effective in the industry. | In a computer-controlled sewing machine including a standard machine frame and exchangeable electronic control circuit plates inclusive of an operation board, a case for receiving a control circuit plate is attached to the machine frame. The circuit plates and the case are provided with coded keying means in the form of pins and holes to guarantee the fastening of a control plate matching a particular model of the sewing machine. | 3 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of and claims priority under 35 U.S.C. § 120 to PCT Application No. PCT/EP2006/005120, filed on May 30, 2006, which claimed priority to EP Application No. 05 011 709.2, filed on May 31, 2005. The contents of both of these priority applications are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The invention relates to a laser processing machine including an optics for beam guidance and for focusing of a laser processing beam.
BACKGROUND
[0003] Laser processing machines are used for material processing and typically includes a laser processing nozzle. The laser beam in laser processing machines is positioned centrally within the laser processing nozzle. The laser processing nozzle adjustment can be performed manually.
SUMMARY
[0004] In one general aspect, a laser processing machine includes a laser that outputs a laser beam, a laser processing head including a nozzle that defines a nozzle bore, a beam guidance and focusing system for directing the laser beam through the nozzle bore of the laser processing head, an illumination system that includes a light source that is distinct from the laser and that produces a light beam that illuminates the nozzle bore, a light detector at the nozzle bore that detects light that exits the nozzle bore, and an evaluation system that receives an output of the light detector and determines a separation between a center of the laser beam when the laser beam is focused at the nozzle and a center of the nozzle.
[0005] Implementations can include one or more of the following features. For example, the light beam can be directed to be collinear with the laser beam.
[0006] The light source can include a laser diode.
[0007] The light beam can be directed by an optical system that includes an optics that widens the light beam, a deflecting mirror that deflects the widened light beam, and a mirror that reflects the light beam deflected from the deflecting mirror so that the light beam is collinear with respect to the laser beam. The deflecting mirror and the mirror can be part of a process light measuring system.
[0008] The light detector can include a screen that receives the light that exits the nozzle bore. The light detector can record an image of the light at the screen. The light detector can receive the light that exits the nozzle bore.
[0009] The evaluation system can determine a center of a spot formed by the light beam at the light detector and a center of a spot formed by the laser beam at the light detector. The light beam can completely illuminate the nozzle bore. The beam guidance and focusing system can include an adaptive mirror.
[0010] In another general aspect, a method of laser processing includes directing a laser beam from a laser through a nozzle bore of a nozzle of a laser processing head, producing a light beam that is distinct from the laser beam of the laser, directing the light beam at the nozzle bore of the nozzle to completely illuminate the nozzle bore, detecting the light from the light beam and the laser beam that exit the nozzle bore, and determining a separation between a center of the laser beam when the laser beam is focused at the nozzle and the center of the nozzle based on the light detected from the light beam and the laser beam exiting the nozzle bore.
[0011] Implementations can include one or more of the following features. For example, directing the laser beam from the laser through the nozzle bore can include directing the laser beam through an adaptive mirror and then through a focusing optics.
[0012] Producing the light beam that is distinct from the laser beam can include producing the light beam from a laser diode.
[0013] Directing the light beam at the nozzle bore can include directing the light beam to be collinear with the laser beam. Directing the light beam at the nozzle bore can include expanding the light beam, deflecting the expanded light beam, and reflecting the deflected light beam to be collinear with the laser beam.
[0014] Determining the separation between the laser beam focus and the nozzle center can include measuring a size of a first spot formed from the light beam that passes through the nozzle to determine a center of the nozzle bore, positioning a focal position of the laser beam at a plane at a lower edge of the nozzle, determining a center of a second spot formed from the laser beam that passes through the nozzle, and automatically adjusting one or more of the laser beam focus and position to center the laser beam on the nozzle.
[0015] In another general aspect, a method of laser processing includes directing a laser beam from a laser through a nozzle bore of a nozzle of a laser processing head, defocusing the laser beam so that the laser beam completely illuminates the nozzle bore, detecting the light from the defocused laser beam that exits the nozzle bore, evaluating the detected light to determine light intensity, and automatically adjusting one or more of the laser beam position and focus and the position of the nozzle to position the laser beam at the center of the nozzle based on the evaluation.
[0016] In a further general aspect, a laser processing machine includes a laser that outputs a laser beam, a laser processing head including a nozzle that defines a nozzle bore, a beam guidance and focusing system for directing the laser beam through the nozzle bore of the laser processing head, an illumination system that produces a light beam that is directed at the nozzle bore of the nozzle such that the light beam completely illuminates the nozzle bore, a light detector at the nozzle bore that views light that exits the nozzle bore, and an evaluation system that receives the output of the light detector and automatically determines the separation between a center of the laser beam when the laser beam is focused at the nozzle and a center of the nozzle based on the light detector output.
[0017] Implementations can include one or more of the following features. For example, the illumination system can include a light source that is distinct from the laser. The illumination system can include a defocusing device that defocuses the laser beam from the laser to produce the light beam that completely illuminates the nozzle bore.
[0018] The laser processing beam can be automatically positioned centrally within a nozzle bore of a laser processing nozzle of the laser processing machine (such as a laser cutting head).
[0019] Advantageously, the nozzle center can be determined by a reference measurement, where one image of the illuminated nozzle and one image of a focused beam are recorded and evaluated. The measurement signals can be used for automatic laser nozzle centering through machine control.
[0020] A separate light source is provided for illuminating the nozzle bore. This is advantageous in that the laser beam designed for laser processing need not be adjusted. A further essential advantage of using a separate light source is the fact that visible light can be used. For this reason, detectors for visible light can be used. The detectors can be manufactured through standard production at little cost. Since the existing optics can be used to couple-in the light beam of the light source, no additional optics is required for coupling-in.
[0021] The method using a separate light source can be technically implemented with a laser diode for generating the beam, an optics for widening the beam, a deflecting mirror, and a mirror for reflecting the light beam co-linearly with respect to the laser processing beam.
[0022] When the deflecting mirror and the mirror are part of a process light measuring device, the invention can be combined with a process light measuring device, and be advantageously integrated in a laser processing machine.
[0023] An image detecting and image evaluating device is of advantage for evaluation.
[0024] The optics for beam guidance and laser beam focusing can include an adaptive mirror that can be used to adjust the illumination.
DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a perspective view of a laser processing machine;
[0026] FIG. 2 is a schematic diagram of a part of the laser processing machine of FIG. 1 showing laser beam guidance and reflection of a light beam for illuminating a nozzle bore;
[0027] FIG. 3 is a schematic diagram of a part of the laser processing machine of FIG. 1 showing another implementation that includes a process light measurement;
[0028] FIG. 4 is a schematic diagram of a part of a nozzle showing the nozzle bore illuminated by a light beam;
[0029] FIG. 5 is a schematic diagram of the part of the nozzle showing the nozzle bore;
[0030] FIG. 6 is a top view of a quadrant sector; and
[0031] FIG. 7 is a schematic diagram of a part of the laser processing machine of FIG. 1 showing another implementation.
DETAILED DESCRIPTION
[0032] FIG. 1 shows the structure of a laser processing machine 1 for laser cutting. The laser processing machine 1 includes a laser 2 that produces a laser beam 5 , a laser processing head 3 that receives the laser beam 5 from the laser 2 , and a workpiece support 4 that supports a workpiece 6 (such as sheet metal). The laser 2 can be any high power pulsed laser, for example, a CO2 laser or a Nd:YAG laser. The laser beam 5 from the laser 2 is guided to the laser processing head 3 using deflecting mirrors, and the laser processing head 3 directs the laser beam 5 onto the workpiece 6 with mirrors.
[0033] The laser beam 5 penetrates through the workpiece 6 to produce a continuous kerf. The workpiece 6 is, in this example, dot-melted or oxidized at one location, and the molten mass is blown out using a cutting gas.
[0034] In case of slow piercing by a ramp, the power of the laser 2 can be gradually increased, reduced, and kept constant for a defined time period until the piercing hole is generated. Both piercing and laser cutting are supported by adding of a gas. Oxygen, nitrogen, compressed air, and/or application-specific gases can be used as cutting gases 7 that are focused or blown into the cutting region to expel or blow away molten material and vapor from the cutting path. The selection of the gas to be used depends on the materials to be cut and on the quality standards that the workpiece must meet.
[0035] At that location where the laser beam 5 is incident on the workpiece 6 , the material is molten and largely oxidized. The produced molten mass is blown out together with the iron oxides. The generated particles and gases can be withdrawn into a suction chamber 9 using a suctioning means 8 .
[0036] Referring to FIG. 2 , the laser processing head 3 (also referred to as a cutting head 3 ) includes a cutting nozzle 10 ′ that defines a cutting nozzle bore 10 . The laser processing machine 1 includes an illumination system 100 having a light source 11 that illuminates the cutting nozzle bore 10 . The light source 11 can be a laser diode that produces a laser beam 14 . Additionally, the illumination system 100 includes a deflecting mirror 12 disposed at an angle from the output axis of the light source 11 , for example, at an angle of 45°, to deflect the laser beam, and a mirror 13 positioned in the path of the laser beam 14 deflected from the deflecting mirror 12 . The mirror 13 is also in the path of the laser beam 5 so that the mirror 13 allows reflection of the laser beam 14 such that the reflected laser beam 14 is collinear with the laser beam 5 of the laser 2 . Towards this end, the laser beam 14 of the light source 11 is widened with a widening lens 15 positioned near an output of the light source 11 such that the laser beam 14 is incident on or near the edge of the mirror 13 . The focal distance of the widening lens 15 and its separation from the mirror 13 are selected such that a focusing optics 16 (for example, a lens or a mirror) placed downstream of the light source 11 is completely or nearly completely illuminated by the laser beam 14 of the laser diode 11 .
[0037] The laser beam 14 produced by the light source 11 can be at any suitable wavelength, for example, it can be at wavelengths in the visible spectrum to facilitate the task of automated laser processing nozzle adjustment. However, the laser beam 14 can be at other wavelengths.
[0038] The focal position of the focusing optics 16 is adjusted using an adaptive mirror 17 positioned between the optics 16 and the mirror 13 until the nozzle bore 10 is completely or nearly completely illuminated by the laser beam 14 . The laser beam 14 thereby grazes the edge of the nozzle bore 10 .
[0039] The illumination system 100 can include an image display 18 , which is disposed directly below the laser cutting nozzle 10 ′, and which shows a spot of a diameter D (see FIGS. 4 and 5 ) whose boundary corresponds to the boundary of the nozzle bore 10 . The image display 18 can be a ground-glass screen or any suitable screen for displaying the image of the laser beam 14 . The laser processing machine 1 can include a detector 200 that detects the image at the display 18 and an evaluation system 202 that receives the output of the detector 200 and evaluates the detector output to determine the center of the nozzle 10 ′. The detector 200 can be a camera and the evaluation system 202 can be include processing logic and memory for analyzing information from the detector 200 .
[0040] In a first step, the nozzle center of the nozzle bore 10 can be determined and evaluated the evaluation system 202 (see FIG. 4 ), which determines the center of the spot of diameter D (which corresponds to the center of the nozzle bore 10 ). In a second step, the focal position of the laser beam 5 is positioned exactly in the plane of the lower edge of the nozzle 10 ′ (see FIG. 5 ). The spot that corresponds to the focus of the laser beam 5 has a diameter D′ (for example, of approximately 0.1 mm). The center of the spot of the laser beam 5 is determined (see FIG. 5 ). The deviation between center of the laser beam 5 ( FIG. 5 ) and the nozzle center as determined using the laser beam 14 can be determined and used for automatic adjustment.
[0041] The illumination system 100 can be installed in the beam guidance of the laser beam 5 at any location of the laser processing machine 1 .
[0042] FIG. 3 shows the combination of an illumination system 100 ′ (similar in design to the illumination system 100 ) with an optical process light measuring system 300 that processes light 5 ′ that can be back-reflected at the workpiece 6 . The illumination system 100 includes a deflecting mirror 12 ′ at an output of the light source 11 , and a mirror 13 ′ in the path of the beam 14 deflected from the mirror 12 ′. The optical process light measuring system 300 includes a photo diode 19 that receives light and electronics 20 that processes data from the photo diode 19 .
[0043] The mirror 13 ′ can have a hole through which the processing laser beam 5 passes. The back-reflected light beam 5 ′ is coupled into the beam guidance through the partially reflecting mirror 12 ′ and the so-called scraper mirror 13 ′. The mirror 13 ′, a (pierce control system (PCS) scraper, is a suitable mirror that is already provided in the laser processing machine 1 and can be additionally used for this purpose. The laser processing machine 1 can be provided with the optical process light measuring system 300 , where the mirror 13 ′ is part of the process light measuring system 300 . The process light measuring system 300 can be conventionally constructed. Measuring systems of this type are distributed, e.g., by TRUMPF GmbH+Co. KG of Ditzingen, Germany, under the name “PCS”. PCS (or pierce control system) is an optical system that measures the process light during piercing (which is a step that can take place prior to laser cutting). In accordance with the selected function in the DIAS-PCS-PC, the piercing process can be controlled using measurement values (soft piercing) and/or the piercing end can be detected (soft and full piercing).
[0044] Back-reflected process light 5 ′ that is generated at the position on the workpiece 6 that is being pierced due to the laser power beam is guided with the scraper mirror 13 ′ to the photo diode 19 , which converts the intensity of the light 5 ′ into a corresponding current. The electronics 20 in the measuring head measures the current from the photo diode 19 and transmits these measurement values in a digital fashion to evaluation electronics that continues to process this data in a corresponding fashion.
[0045] In another implementation, instead of the laser beam 14 , a weakened laser processing beam 5 can also (or alternatively) be used for illuminating the nozzle bore 10 . In this case, a CO 2 laser light-sensitive camera or at least a CO 2 laser light-sensitive quadrant detector can be used as the sensor at the output of the nozzle bore 10 if the laser 2 is a CO 2 laser.
[0046] The quadrant detector can be used as follows.
[0047] In a first implementation, the laser beam 5 is defocused until it fills the nozzle bore 10 of the laser processing head 3 . The laser beam 5 is displaced using the optical elements of the beam guidance (for example, using mirror 13 , mirror 17 , and/or focusing optics 16 ) until the signal, e.g., in the −X-quadrant disappears.
[0048] The value of the displacement is stored. The value in +X-direction is subsequently determined by movement along the X-axis. The center of the nozzle 10 ′ is the average value of the two obtained values. Displacement in the Y-direction is performed analogously. Then, the focal point of the beam 5 is imaged on the image detector or display 18 by means of the mirror 17 . The adjustment means in the laser processing head 3 is then adjusted such that all four quadrants display the same measurement values (see FIG. 6 ). The laser beam 5 is centered.
[0049] In a second implementation, when the focusing optics 16 is stationary, the nozzle 10 ′ can be moved. The small imaged beam 5 is displaced on the image detector or display 18 , such that all four quadrants of the image detector or display 18 display the same measurement value. The laser beam 5 is then enlarged through defocusing by the mirror 17 , such that it fills the nozzle bore 10 . The nozzle 10 ′ is then adjusted with respect to both axes (the X- and Y-axes) until all four quadrants show the same measurement value.
[0050] Referring also to FIG. 7 , in other implementations, the image display 18 can alternatively be an image display and detector 180 that can both display the light and sense the light impinging upon its surface from the laser beam 14 and the laser beam 5 (for example, the image display and detector 180 can include a camera). In these implementations, the evaluation system 202 can be directly connected to image display and detector 180 .
OTHER EMBODIMENTS
[0051] It is to be understood that while the invention has been described in conjunction with the detailed description thereof, the foregoing description is intended to illustrate and not limit the scope of the invention, which is defined by the scope of the appended claims. Other aspects, advantages, and modifications are within the scope of the following claims. | A laser processing machine includes a laser that outputs a laser beam, a laser processing head including a nozzle that defines a nozzle bore, a beam guidance and focusing system for directing the laser beam through the nozzle bore of the laser processing head, an illumination system that produces a light beam that is directed at the nozzle bore of the nozzle such that the light beam completely illuminates the nozzle bore, a light detector at the nozzle bore that views light that exits the nozzle bore, and an evaluation system that receives the output of the light detector and automatically determines the separation between a center of the laser beam when the laser beam is focused at the nozzle and a center of the nozzle based on the light detector output. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a CIP of an application Ser. No. 08/542,975, filed Oct. 13, 1995, (DP-6485), now abandoned.
FIELD OF INVENTION
This invention relates to improvements in making lofty bonded battings, such as are used as filling material and insulation.
BACKGROUND ART
Polyester fiberfill filling material (sometimes referred to herein as polyester fiberfill) has become well accepted as a reasonably inexpensive filling and/or insulating material for filled articles, such as cushions and other furnishing materials, including bedding materials, such as mattress pads, quilts, comforters and including duvets, in apparel, such as parkas and other insulated articles of apparel and sleeping bags, because of its bulk filling power, aesthetic qualities and various advantages over other filling materials, so is now manufactured and used in large quantities commercially.
Filling materials are often of staple fiber, sometimes referred to as cut fiber in the case of synthetic fiber, which is first crimped, and is provided in the form of continuous bonded batts (sometimes referred to as battings) for ease of fabrication and conversion of staple into the final filled articles. Traditionally, bonded batts have been made from webs of parallelized (staple) fiber that preferably comprise a blend of binder fibers as well as of regular filling fibers, which can consequently be referred to as load-bearing fibers, such as poly(ethylene terephthalate) homopolymer, often referred to as 2G-T. These webs are made on a garnett or other type of card (carding machine) which straightens and parallelizes the loosened staple fiber to form the desired web of parallelized, crimped fibers. The webs of parallelized fibers are then built up into a batt on a cross-lapper. The batt is usually sprayed with resin and heated to cure the resin and any binder fiber to provide the desired bonded batt. The resin is used to seal the surface(s) of the batt (to prevent leakage) and also to provide bonding. The use of binder fiber intimately blended with the load-bearing fiber throughout the batt has generally been preferred because such heating to activate the binder material (of the binder material) can provide a "through-bonded" batt. If binder fiber is used, and if a suitable shell fabric can prevent leakage of fibers, then the resin treatment may be omitted, and is in some instances, for example, for some sleeping bags. This simplified explanation is the normal way most bonded batts are now made, because it is not expensive and is adequate for many purposes, especially when dense batts are desired. There has been a limit, however, to the ability to make lofty batts, such as are often desirable for some end-uses, by this normal procedure.
Consequently, some have preferred to use an air-laying process for preparing a lofty batt, which is then bonded. Such an air-laying process does indeed provide a way to overcome the deficiency mentioned of the normal batt-making process that has been used hitherto for making dense batts. Air-laying is, however, more costly and requires different equipment, so it has been desirable to find a less expensive way to overcome the deficiencies of the normal batt-making process without the need for more expensive equipment.
As indicated, the staple fiber is crimped for use as fiberfill. Indeed, the crimp is important in providing the filled articles with bulk and support. Generally, the crimp has been provided mechanically, by stuffer box crimping of a precursor continuous filamentary tow, as has been described in the art, as this is a reasonably inexpensive way of imparting crimp to an otherwise linear synthetic filament.
SUMMARY OF THE INVENTION
The present invention provides a new and improved way to make bonded batts by using essentially the same equipment used previously in the normal batt-making process, but also providing an ability to provide loftier (less dense) bonded batts, and thus to overcome the important deficiency mentioned above. Improved loft is provided, according to the invention, by using a blend of mechanically-crimped fibers and of bicomponent fibers of helical configuration (often referred to simply as "helical crimp" or "spiral crimp" in the art and herein) and/or the provision of lofty webs by use of a randomizer in the carding step, otherwise following essentially the normal process of making bonded batts, especially "through-bonded" batts. These aspects may be used separately or in combination.
According to one aspect of the present invention, therefore, I provide a preferred process for preparing a bonded batt, comprising forming a feed blend of mechanically-crimped staple fibers intimately mixed with bicomponent staple fibers having a helical configuration, in amount by weight about 5 to about 30% of the blend, preparing a continuous batt from said feed blend by carding the feed blend to provide a web of parallelized fibers, passing the resulting carded web to a randomizer to provide a web of randomized fibers, cross-lapping one or more webs of randomized fibers to provide a batt, said batt having an upper face and a lower face, advancing said batt through a spray zone, whereby at least one face of the batt is sprayed with resin, in total amount about 5 to about 30% of the weight of the sprayed batt, including the resin, heating the sprayed batt in an oven to cure the resin, and cooling the resulting batt.
According to another aspect, I provide a process for preparing a bonded batt, comprising forming a feed blend of mechanically-crimped staple fibers intimately mixed with bicomponent staple fibers having a helical configuration, in amount by weight about 5 to about 30% of the blend, preparing a continuous batt from said feed blend by carding the feed blend to provide a web of fibers, cross-lapping one or more webs of such fibers to provide a batt, said batt having an upper face and a lower face, advancing said batt through a spray zone, whereby at least one face of the batt is sprayed with resin, in total amount about 5 to about 30% of the weight of the sprayed batt, including the resin, heating the sprayed batt in an oven to cure the resin, and cooling the resulting batt.
Preferably, to provide "through-bonded" batts, such feed blends comprise, intimately mixed therein, binder fibers having binder material that bonds at a temperature that is lower (i.e., has a softening point lower) than any (i.e., lower than the lowest) softening point of the said staple fibers in the feed blend, in amount by weight about 5 to about 30% of the blend, and the sprayed batt is heated in the oven to activate the binder material as well as to cure the resin.
As indicated, in certain instances, resin-spraying may be omitted. So, according to another aspect, I provide a process for preparing a bonded batt, comprising forming a feed blend of mechanically-crimped staple fibers, in amount by weight about 40 to about 90%, intimately mixed with bicomponent staple fibers having a helical configuration, in amount by weight about 5 to about 30%, and with binder fibers having binder material that bonds at a temperature that is lower than the lowest softening point of the said staple fibers in the feed blend, in amount by weight about 5 to about 30%, preparing a continuous batt from said feed blend by carding the feed blend to provide a web of parallelized fibers, passing the resulting carded web to a randomizer to provide a web of randomized fibers, cross-lapping one or more webs of randomized fibers to provide a batt, heating the batt in an oven to soften the binder material, and cooling the resulting batt.
According to a further aspect, likewise, I provide a process for preparing a bonded batt, comprising forming a feed blend of mechanically-crimped staple fibers, in amount by weight about 40 to about 90%, intimately mixed with bicomponent staple fibers having a helical configuration, in amount by weight about 5 to about 30%, and with binder fibers having binder material that bonds at a temperature that is lower than the lowest softening point of the said staple fibers in the feed blend, in amount by weight about 5 to about 30%, preparing a continuous batt from said feed blend by carding the feed blend to provide a web of fibers, cross-lapping one or more webs of such fibers to provide a batt, heating the batt in an oven to soften the binder material, and cooling the resulting batt.
As will be seen, merely randomizing the fibers provides an improvement, so, according to this aspect, there is provided a process for preparing a bonded batt, comprising carding feed fibers to provide a web of parallelized fibers, passing the resulting carded web to a randomizer to provide a web of randomized fibers, cross-lapping one or more webs of randomized fibers to provide a batt, said batt having an upper face and a lower face, advancing said batt through a spray zone, whereby at least one face of the batt is sprayed with resin, in total amount about 5 to about 30% of the weight of the sprayed batt, including the resin, heating the sprayed batt in an oven to cure the resin, and cooling the resulting batt.
Further provided is such a process wherein said feed fibers comprise, also, intimately blended therewith in amount by weight about 5 to about 30%, binder fibers having binder material that bonds at a temperature that is lower than the lowest softening point of the said feed fibers, whereby a continuous batt is prepared from the resulting blend by carding the resulting blend to provide a web of parallelized fibers, passing the resulting carded web to a randomizer to provide a web of randomized fibers, cross-lapping one or more webs of randomized fibers to provide a batt, advancing said batt through a spray zone and oven, whereby the sprayed batt is heated in the oven to cure the resin and to soften the binder material, and cooling the resulting batt.
Also provided, likewise, according to another aspect, is a process for preparing a bonded batt, comprising forming a feed blend of mechanically-crimped staple fibers intimately mixed with binder fibers having binder material that bonds at a temperature that is lower than the lowest softening point of the said staple fibers in the feed blend, in amount by weight about 5 to about 30% of the blend, preparing a continuous batt from said feed blend by carding the feed blend to provide a web of parallelized fibers, passing the resulting carded web to a randomizer to provide a web of randomized fibers, cross-lapping one or more webs of randomized fibers to provide a batt, heating the batt in an oven to soften the binder material, and cooling the resulting batt.
"Through-bonded batts" are preferred, such as are made by incorporating binder fibers in amounts of about 5 to about 30% by weight in the feed blend of staple fibers, such as polyester fibers, which are themselves preferred staple fibers, but the invention has also shown advantages with feed fibers that do not include binder-fibers as indicated with fiber "A" in Example 1, hereinafter.
Sheath/core bicomponent fibers are preferred as binder fibers, especially bicomponent binder fibers having a core of polyester homopolymer and a sheath of copolyester that is a binder material, such as are commercially available from Unitika Co., Japan (e.g., sold as MELTY). Preferred proportions of the resin sprayed are about 5 to about 18%, on the indicated basis, while preferred amounts of binder fiber are about 10% to about 20% (by weight of the feed blend) and correspondingly about 90 to about 80% of the (other) staple fibers, which are preferably polyester, and may be 2G-T, together with any bicomponent fibers of helical configuration.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic illustration of how a garnett with a randomizer roll may be operated according one aspect of the invention.
FIG. 2 is a schematic illustration of how a garnett may be operated according to such aspect of the invention with a pair of randomizer rolls.
FIG. 3 is a schematic illustration of a cross-lapper operation.
DETAILED DESCRIPTION OF THE INVENTION
As indicated hereinabove, the process of the invention is essentially similar to the normal process of making bonded batts used conventionally hitherto, but with important exceptions. The improvements in thickness (lowered density) and increased insulation are significant and are shown hereinafter by the comparative data in the Examples.
Thus, the fibers in the carded web are preferably randomized, and preferably by being processed by a randomizer after the carding step and preferably before the cross-lapping step. A randomizer is not an expensive addition to a carding machine. Indeed, nonwoven random cards have been suggested to turn the fibers into the cross-direction (CD), and thus increase the CD:MD (cross-direction:machine direction) of the fibers in webs for flat nonwovens and so randomizing rollers have been available, e.g., from John D. Hollingsworth-on-Wheels in Greenville, S.C., from Ramisch Kleinewefers, Spinnbau Bremen, Germany, and from Ta You Machinery Co. Ltd., in Tao-Yuan, Taiwan. When randomizing rollers have been used in prior processes for making webs for flat non-wovens, the randomized fibers in the webs have subsequently been flattened, for instance by calendering during a calender-bonding process or by compressing the non-woven web after saturation with resin during a saturation-bonding process. Randomizers are not believed to have been used for making lofty bonded batts, nor to overcome the deficiencies of the equipment hitherto normally used for making lofty bonded batts. This is surprising in view of the improvements I have achieved and in view of the simplicity of my change from the normal process.
This aspect of the invention will now be described with reference to the accompanying drawings, in which like elements are referred to by similar numerals. FIG. 1 illustrates the arrangement of three cylinders (sometimes referred to as rolls) arranged in juxtaposition for a garnetting step according to this aspect of the invention with their axes horizontal, showing from the left a main cylinder 11, a doffer 12, and a randomizer 13, rotating in the directions indicated (main cylinder and randomizer clockwise, with doffer counterclockwise), and with their cylindrical surfaces covered with appropriate card clothing, with teeth oriented as indicated (main cylinder teeth 21 oriented in direction of rotation, but doffer teeth 22 and randomizer teeth 23 opposite to directions of rotation). Thus, a (carded) web 14 is carried by the teeth 21 on main cylinder 11, stripped therefrom by the teeth 22 on doffer 12, and then transferred from the doffer teeth 22 to the randomizer's teeth 23. The randomizer 13 is rotated at a surface speed that is much reduced from the surface speed of the doffer 12, so the parallelized fibers in the web 14 become rearranged in the nip 15 between the doffer 12 and the randomizer 13, and the resulting web 16 carried by the teeth 23 on the randomizer 13 is loftier and contains randomly-oriented fibers, many of which are at significant angles to the machine direction (direction of travel of the web), and can be considered to be vertical or at least have a significant vertical component in relation to a horizontal web. The surface speed of the randomizer 13 should generally be less than 2/3 that of the doffer 12, i.e., doffer surface speed being at least about 1.5× that of randomizer, and often about 2.5× or more, which is generally at the higher end of the range that has been used (for different purposes in making flattened fibrous masses with increased CD:MD ratios for non-wovens). When making lofty bonded batts according to my invention, I do not want to flatten the web, i.e., to remove this vertical component or orientation of the randomized fibers, in contrast to prior processes for making flat non-woven webs that have used a randomizer and then compressed the web to flatten the randomized fibers. This randomized web 16 then drops onto a horizontal conveyor 17, and is transferred to the next stage.
The garnett illustrated in FIG. 2 is essentially similar to that of FIG. 1, except that two randomizers 13 and 18 are located in series between doffer 12 and conveyor 17, the second randomizer 18 rotating in a counterclockwise direction, with its teeth 24 oriented opposite to the direction of rotation. This alternative is illustrated because machinery with a pair of randomizer rolls has been available commercially in relation to carding flat webs, because it has provided a capability for better control of CD:MD (cross-direction:machine direction) fibers in a flat horizontal web (by varying the relative speeds of the randomizer rolls), but I do not believe that using a second randomizer roll offers significant benefit according to the present invention, which derives benefit from increasing and maintaining vertical components of orientation and providing a lofty web, rather than a flat web. I prefer to operate any second randomizer 18 at a slightly slower surface speed than that of the first randomizer 13.
FIG. 3 illustrates a conventional cross-lapper, and further description appears to be unnecessary.
Other features of the invention are mostly conventional, except in regards to the improvement in lofty bonded batts obtained by using a proportion of fibers having helical crimp blended into the feed fiber, as described herein. Hernandez et al. U.S. Pat. No. 5,458,971 and application Ser. No. 08/542,974 filed Oct. 13, 1995 and now allowed (respectively DP-6320 and DP-6320-C) describe preferred bicomponent fibers having helical configuration and their use as filling fibers. Such fibers, or other fibers having helical crimp (configuration), are preferably blended into the feed fiber in amount about 5 to about 30% of the feed fiber, especially about 10 to about 20%, by weight. Several bicomponent fibers having a helical configuration are disclosed in the art. This configuration has often been referred to as crimp (because most synthetic fibers obtain their desired non-linear configuration by being mechanically-crimped). In fact, the term "spiral crimp" has been used extensively, although the term "helical" is more correct. The configuration is derived from the eccentric arrangement of the components of the fiber. A side-by-side arrangement is generally preferred.
The invention will be further described in more detail with reference to polyester fiberfill, which is preferred, and to other preferred elements and features, such as preferred binder fibers and helically-crimped fibers, although it will be recognized that other fibers may also be used and there is no reason to limit the invention only to those fibers that are preferred.
Reference may be made to the art, such as referred to herein, for conventional features such as preferred feed fibers (their deniers, cross-sections, blends thereof), and equipment and processing features, including U.S. Pat. No. 5,225,242 and application Ser. No. 08/396,291, filed Feb. 28, 1995 (Frankosky et al. DP-6045 and DP-6045-A), and the art referred to therein. Frankosky et al. application Ser. No. 08/406,355, filed Mar. 17, 1995, now allowed, discloses useful binder materials and fibers. Kerawalla, U.S. Pat. Nos. 5,154,969 and 5,318,650 discloses useful binder fibers and processes. Other disclosures of batts, batt-making and their features include, for example, U.S. Pat. Nos. 5,104,725 (Broaddus), 5,064,703 (Frankosky et al.), 5,023,131 (Kwok), 4,999,232 (LeVan), 4,869,771 (LeVan), 4,818,599 (Marcus), 4,304,817 (Frankosky), and 4,281,042 (Pamm), and the references disclosed therein.
The invention is further illustrated in the following Examples; all parts and percentages are by weight unless otherwise indicated. The garnett was supplied by Ta You Machinery Co. Ltd., Tao-Yuan, Taiwan ROC. The cross-lapper used was supplied by Asselin SA, Elbeuf, France. Randomizer rolls were supplied by Ta You Machinery Co. Ltd., and by John D. Hollingsworth on Wheels, Greenville, S.C. CLO ratings are conventional and described, e.g., by Hwang in U.S. Pat. No. 4,514,455.
EXAMPLE 1
Staple fiber and blends as indicated hereinafter in the following Table 1 and explanatory notes were processed into bonded battings by the following procedures, with and without using a randomizer roll, for comparison, and otherwise following essentially the procedure described in Example 5 of copending application Ser. No. 08/542,974 (DP-6320-C) filed Oct. 13, 1995 and now allowed by Hernandez et al. In other words, both for making battings according to the invention (using a randomizer roll and/or bicomponent fiber of helical configuration) and for comparisons, the blends were processed on a garnett and then cross-lapped and sprayed with half the indicated amount of an acrylic resin on the top side and carried by conveyor to the first path of a three-path oven to cure the resin and activate the binder fiber at 150° C.; at the exit of the first path, the batting was turned upside-down and the other side of the batting was sprayed with the other half of the same acrylic resin to make up the total resin pickup; the batting was carried by another conveyor to the second path of the oven and
For making battings according to the randomizer aspect of the invention during the garnetting process, the web that was removed from the main cylinder of the garnett by the doffer was delivered from the doffer to a randomizer roll, as shown in FIG. 1 of the accompanying drawings, at a speed 2.6× the surface speed of the randomizer roll. Because the speed of the doffer was so much faster than the speed of the randomizer, the orientation of the fibers in the web was rearranged from a flat parallelized web to a loftier, thicker web with randomized fibers, several being oriented in a vertical direction (at right angles to both the machine and cross-directions, referred to generally as MD and CD). This loftier web (loftier than the comparison webs made by garnetting without any randomization) was then cross-lapped (to build up basis weight) and sprayed with resin, and heated in similar manner to the comparison webs.
The improvements in thickness and insulating properties achieved by use of the invention can be seen from the data given in Table 1. It will be noted that the improvements obtained by the invention were step-wise, improvements being achieved by using either the randomizer (Rand), or by incorporating fiber of helical crimp in minor amount in a blend of feed fiber, as indicated under BiC (for BiComponent), and the best results were obtained by using both aspects.
TABLE 1______________________________________ Thickness CLOStaple BiC Resin BW in/ CLO/Rand Type % % (oz) in oz/yd.sup.2 CLO oz/yd.sup.2______________________________________No A 0 12.3 4.82 0.89 0.18 2.58 0.54Yes 0 12.1 4.51 0.87 0.19 2.55 0.57Yes 15 9.8 4.39 0.89 0.20 2.62 0.60No B 0 20.9 4.65 0.71 0.15 2.63 0.57Yes 0 26.2 4.95 1.02 0.21 2.99 0.60Yes 15 25.0 4.66 1.04 0.22 2.89 0.62______________________________________
EXAMPLE 2
Staple fiber blends as indicated in Table 2 were processed into bonded batts according to the invention following essentially similar procedures as described in Example 1, except that the web was passed from the doffer to the first of a pair of randomizer rolls as illustrated in FIG. 2 herein, and then to the second randomizer roll, which was operated at a slightly slower speed. Details and measurements of properties are given in Table 2.
TABLE 2______________________________________ Thickness CLOStaple BiC Resin BW in/ CLO/Rand Type % % (oz) in oz/yd.sup.2 CLO oz/yd.sup.2______________________________________Yes C 0 11.0 3.17 0.48 0.15 1.75 0.55Yes 15 14.1 2.86 0.52 0.18 1.70 0.59Yes 30 10.1 2.92 0.56 0.19 2.06 0.71______________________________________
Explanatory Notes
The following abbreviations were used in the Examples:
"Rand" indicates whether a randomizer was used, or the experiment was a comparison performed without randomizing, but under otherwise similar conditions;
"BiC" indicates the amount of bicomponent fiber, which was the 9 dpf, 3 inch, slickened, 3-void, helical crimp bicomponent polyester fiber of Example 1 of U.S. Pat. No. 5,458,971;
"BW" indicates the "Batting Weight" of the batt, i.e., after spraying on resin, the total percentage amount sprayed being indicated under "Resin";
"Thickness" and "CLO" are both given in absolute values and after being normalized to equivalent batting weights per unit area;
"Staple" fibers and blends are available commercially, as follows:
A--slickened 5.5 dpf, 3-inch cut length (7.5 cm), 7-hole
B--55% slickened 3.6 dpf, 2.5-inch cut length (6.3 cm), hollow
27% slickened 1.65 dpf, 2.5-inch cut length (6.3 cm)
18% 4 dpf, 2.5-inch cut length (6.3 cm) MELTY 4080
C--55% slickened 1.65 dpf, 2-inch cut length (5 cm)
27% 1.65 dpf, 2-inch cut length (5 cm)
18% 4 dpf, 2-inch cut length (5 cm) MELTY 4080
The regular fiberfill above, i.e., other than binder fiber, was 2G-T polyester of solid cross-section, unless otherwise indicated; MELTY 4080 is a sheath/core binder fiber, referred to in the art, and commercially available from Unitika Co., Japan; the fibers used were all of round periphery and none were slickened unless indicated. | Lofty battings are prepared by a process involving carding to make one or more webs of fibers, preferably using a blend of mechanically-crimped filling fibers with bicomponent fibers of helical configuration, and that preferably also contains binder fibers, the fiber orientations preferably being randomized in the web(s) before cross-lapping to build up the batt, and preferably followed by spraying with resin and curing, thus providing a bonded batt in which the loft is improved by the presence or the different crimp configurations and/or randomized orientations that are fixed in the fibers in the bonded batt. | 3 |
FIELD OF THE INVENTION
The present invention relates to chimney flashing.
DESCRIPTION OF THE PRIOR ART
Flashing is used to prevent rain water from seeping into a brick building. Flashing is used, for example, where two roof planes come together to form a gutter. The present invention relates to flashing used around chimneys which are built of brick or brick-like articles.
To form a waterproof seal along a course of bricks, flashing made of easily-bent sheet metal is often used. The sheet metal is typically aluminum or copper. The flashing metal is bent to form a narrow lip at right angles to the main part of the sheet. This lip is fastened into the brick work by inserting the lip into wet mortar between the courses; when the mortar sets hard the sheet metal lip is held to the brick wall. The flashing may be inserted during brick laying, or later. If later, the mortar will need to be removed from between two courses of brick.
Flashing on chimneys presents special problems because of the roof through which the chimney partially or fully protrudes. The chimney will meet the roof at an angle along two sides of the chimney; these angled sides present the problem.
Flashing must run around the chimney to prevent water from getting under the shingles or covering of the roof. Typically the flashing extends a short distance along the roof surface over the covering. At the angle of the roof and chimney the flashing bends up to a horizontal angle. It runs a short distance up along the bricks, and then the bent lip is inserted into the mortar between one brick and another.
This is not particularly troublesome on the non-angled sides, but along the angled sides it is very difficult to fit the metal flashing into the brickwork due to the many steps. As the roof rises, the flashing must jump from one course of brick to a higher or lower course. At each jump the flashing must be cut and bent to fit.
To fit many such steps requires cutting the flashing to the shape of the brick steps while including material for the lips. Depending on the pitch of the roof, the number of bricks between steps will vary; this complicates the pattern further. If a large sheet of metal is used, the pattern is complex; if small sheets are used, many joints will result, leading to an increased chance of leaks.
Despite the great work involved in setting metal flashing into a chimney, the results are often not good. Skill in both layout and cutting of sheet metal are needed. At corners and rises, the sheet metal will either overlap on the inside of a right angle bend (or else require two 45 degree cuts to prevent overlap there) or leave a gap on the outside of a right angle bend. The double thickness of an overlap may cause trouble in setting bricks of the two courses close enough. A gap, naturally, invites the water infiltration which the flashing is installed to prevent.
Even if the work is done properly, the results are often unsatisfactory because leaks can develop. Leaks result from differential thermal expansion of the metal and brick, dents to the metal, corrosion, etc.
Because of the drawbacks of custom-making the flashing, several persons have developed flashing systems which are prefabricated to some extent. Several patents relate to such prefabricated flashings for chimneys. U.S. Pat. No. 2,417,039 of Albaugh shows a metal or plastic sheath for a chimney top. This prevents water from damaging the top of the chimney. The sheath ends above the roof line.
A related U.S. Pat. No. is that of Miller U.S. Pat. No. 3,363,369). Miller teaches a vertically elongated metal shield surrounding a chimney which rises from the roof flashing up to a certain level. This shield is disposed beneath a flashing strip which runs around the chimney. The strip is basically an L-shaped piece which runs down over the shield to exclude water, and runs horizontally between bricks. The strip runs completely around the chimney to discourage leaks.
Both the Albaugh and the Miller inventions have the drawback of requiring customized sheet metal work. Also, the metal parts are subject to damage. Moreover, they may be considered unsightly because they cover brick with large sheet metal shields.
U.S. Pat. No. 1,782,246 of Schneider discloses prefabricated metal flashing in sections. The sections are of three types which fit together and overlap. The types are straight runs, right corners and left corners.
Schneider's flashing consists of the flashing proper, which is embedded in the mortar between brick courses and includes a downwardly extending lip, and the counterflashing which is inserted between the brick wall and the flashing lip. The counterflashing is thus removable. The flashing also includes a drip flange which extends from the surface of the brick above the lip and diverts rain water.
Schneider makes no provision for risers, that is, flashing which changes level from one course to another (steps). This means that the flashing will not closely follow a roof line in a typical chimney installation, where the chimney protrudes through a pitched roof, or through the ridge line of a roof. Thus the appearance of the chimney is affected, as with the two other prior art patents.
None of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed.
All of the above inventions utilize sheet metal, and their designs are predicated on this material. However, as noted above, sheet metal has several shortcomings. It corrodes in time, and requires paint to match the color of brickwork. The metal must be relatively thick and heavy to avoid bends and dents during shipment and construction, which would make the flashing unusable. The thickness means that the flashing may be strong enough to break itself loose from the mortar in which it is embedded, when temperature changes cause differential expansion.
Another drawback of metal for a system such as Schneider's is that sheet metal is hard to work in the field, where special equipment is lacking. Bending, sawing and cutting sheet metal are all awkward operations requiring somewhat specialized tools or fixtures. For example, if the metal is thin enough to be cut with metal shears, a bent piece is hard to cut around the bend; if it is thick enough to be hacksawed, it is again liable to bending unless very thick indeed.
Accordingly, one object of the present invention is flashing embedded between brick courses to which additional sheet counterflashing may be easily mated without mortar or adhesives.
Another object of the present invention is flashing which does not interfere with the firm adhesion of one course of bricks to another.
A further object of the present invention is flashing which is preformed to fit various brick configurations, so to avoid time-consuming cutting and bending.
Another object of the present invention is flashing which will not leave gaps or overlaps at corners.
An additional object of the present invention is flashing which requires no painting to match brick in color.
Still another object of the present invention is flashing which is not liable to damage by bending or crushing and which is easy to work.
A final object of the present invention is flashing which is easily cut to length with readily available tools.
These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
SUMMARY OF THE INVENTION
The present invention is preformed plastic chimney flashing which runs along mortar joints between brick courses.
In cross section, the flashing includes a horizontal plate embedded in the mortar between two courses of bricks, and a lip extending downward from the outside edge of the plate. The plate, which extends across the full width of a brick, has holes for adhesion of mortar on either side of the plate. The lip is intended to cover ordinary metal flashing, which inserts between the lip and the brick wall.
The flashing is preformed into several shapes adapted to cover straight runs, steps, corners, and ridge cap bricks. No forming or bending is required at the construction site, only cutting to length for allow for some overlap.
The lip includes a ridge on the lower inside edge to help seal against weather.
The plastic is colored, weatherproof, flexible, and of such consistency that it may easily be cut with a knife.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an environmental perspective view of the invention embedded in the brick work of a chimney. The environment is shown in phantom view. Metal flashing is shown inserted under the lip of the plastic flashing of the invention.
FIG. 2 is a perspective cross-sectional view of a brick wall with the plastic flashing of the invention embedded therein, showing the plate, lip, and the ridge at the bottom of the lip.
FIG. 3 shows the several special sections of the present invention: FIG. 3a shows a ridge cap for a single brick; FIG. 3b shows a riser; and FIG. 3c shows a corner piece.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an overview of the instant invention, flashing, in use. A chimney C, made of bricks B, protrudes through a roof R. Metal counterflashing L extends around the perimeter of the chimney C to prevent rain water from running under the shingles S covering the roof R. The metal flashing extends up the sides of the chimney C to the flashing of the instant invention.
The flashing comprises two main parts, a plate 10 and a lip 20. These parts are also shown in FIG. 2.
The plate 10 is disposed between two neighboring bricks. These two bricks may lie side by side, or above and below one another; the plate 10 may be horizontal or vertical. The plate is set into the mortar M (which cements the adjacent bricks) during brick laying. Holes 12 in the plate 10 allow the mortar adhering to adjacent bricks to penetrate the plate 10, so that adjacent bricks are cemented together by continuous mortar. Because of these holes 12, the plate 10 may have a width equal to the depth of one brick B, and so extend completely across one course of the brick work. The plate 10 will then be firmly held.
The plate 10 runs in an unbroken path around the chimney C, close to the roof R.
The lip 20, which is about half an inch wide, extends downward or sideways from the plate 10. The lip 20 covers the upper edge of the counterflashing L to prevent rain water from running between the counterflashing L and the chimney C or roof R.
The flashing is preferably molded of relatively soft plastic, which has several advantages over the usual metal flashing. Plastic will not dent; it is easily cut and does not leave sharp dangerous edges; it may be colored to match the brick, or to have a pleasant contrasting color; it need not be painted periodically by climbing onto a roof top; and having a lower elastic modulus than metal, it is less likely to break loose from the mortar M by differential temperature expansion.
The ideal plastic material would be flexible even at low temperatures; easily cut with a carpet knife, shears, or the like; resistant to weather and sunlight; and inexpensive.
The use of molded plastic makes possible a major advantage of the present invention, that the flashing surfaces are continuous.
(In this specification and in the following claims, the word "continuous" means without gaps, openings, seams, joints, fasteners, or overlaps. The word "continuous" does not, however, exclude bends, curves, edges, or angles. "Continuous in the region of" a thing means that no gaps, openings, seams, joints, fasteners, or overlaps exist very near to or adjacent to that thing; or, the structure is continuous in that region. Also, if one region or structure is said to be continuous with another, it means that no obstructions as listed above separate those two regions.
Thus, continuity as defined herein means that from any point within the material of the structure (here, plastic), one could reach any other nearby point within the structure in the specified region by traveling through the material of the structure and never having to leave that structural material to pass through another material (e.g., air or adhesive).
This specification's definition of continuity is essentially the same as the mathematical definition of the word, especially the topological definition.)
Since the molded flashing surfaces are continuous in the present invention, there is no danger of leakage between adjacent sections of flashing as there is with sheet metal flashing. Sheet metal flashing cannot be made continuous in the regions of the brick corners. To cover the same brick surface areas as the molded plastic flashing of the present invention, sheet metal must have overlapped lips at acute bends, and must have additional pieces to cover the corner gaps left in the lips at an obtuse bend. Sheet metal flashing lips would, in addition, need to be soldered to have the same water-impervious character as the continuous molded plastic lips of the present invention. Soldering would of course be very unlikely in view of the great work involved.
Another feature of the instant invention, shown in FIG. 2, would also be impossible with sheet metal. This is the ridge 22, which comprises a thickened portion of the lip 20. The ridge 22 allows the lower edge of the lip 20 to closely seal the counterflashing L against water, while allowing the counterflashing L to be easily inserted and pulled from the slot space 24 defined by the outer surface of the brick B and inside surface of the lip 20.
The flashing may be contoured to remain at a small distance above the roof line. The counterflashing L need only rise a bit more than the height of one brick above the roof R, unless the roof pitch is quite steep. Thus the visual impact of the flashing is minimal. If the plastic of the flashing is colored to match the bricks B, the flashing will be almost invisible.
If many identical houses are to be erected, the entire flashing can be molded as one unit. This situation is unlikely, though. To accommodate the flashing to the demands of custom design, it may be made in prefabricated sections.
Such sections will need to be joined in some way. To avoid the need for fasteners and glue, they may be simply overlapped. The overlaps, to avoid leakage, should run vertically across horizontally-extending sections of the lip 20. The amount of overlap might be about a half-inch.
The preferred set of sections are partially shown in FIGS. 3a-3c. Not shown in FIGS. 3a-3c is a simple straight section; this section will be clear to the reader from the other figures.
FIG. 3a shows a cap section 30. This section is set upon the uppermost brick in a region, for example, at the ridge line of the roof R. FIG. 1 also shows the position of a cap section 30.
The cap section 30 includes an upper horizontal plate 32, left and right side plates 34 and 36, and short lower plates 38. (As with all the sections, the lips attached to the various plates are contiguous, and, due to the molded construction, continuous.) The lower plates 38 provide for overlap with the adjacent sections on either side, which could be a straight section or another type as discussed below.
A riser section 40 is shown in FIG. 3b. This comprises an upper plate 42, lower plate 46, and a side plate 44 joining them. To fit all installations, the riser section will come in two varieties, the one pictured and another which is similar to the one shown but mirror reversed.
(If an object is said in this specification or claims to be "mirror reversed", it means that a new object is generated which is identical in appearance to the mirror image of the old object.)
The riser sections which are mirror images of one another can be denoted "left-hand" and "right-hand" sections, but these designations are totally arbitrary, since there is no connection between either one and the human hand. These phrases are nevertheless useful and commonly used for distinguishing mirror image items, such as shoes.
A corner section 50 is shown in FIG. 3c. Here there is a plate 52 lying in a single plane (but not rectangular), and two lips 54 and 56 which are mutually perpendicular. Here again, another section is generating by mirror reversing the corner section pictured.
As shown, the corner section may be arranged to cover one brick by extending across and along a brick horizontally.
Thus a total of six sections will cover any situation. Alternatively, the cap section could be replaced by two mirror-image riser sections.
It is to be understood that the present invention is not limited to the sole embodiment described above, but encompasses any and all embodiments within the scope of the following claims.
In particular, "brick" herein means any brick-like object used in making chimneys, walls or the like.
Also, the present invention is clearly not restricted to chimneys. Any brick wall near a roof, or any brick wall in need of flashing, may use the present invention. | Preformed plastic chimney flashing includes a horizontal plate embedded in the mortar between two courses of bricks, and a lip extending downward from the outside edge of the plate. The plate, which extends across the full width of a brick, has holes for adhesion of mortar on either side of the plate. The lip is intended to cover ordinary metal flashing, which inserts between the lip and the brick wall. The lip includes a ridge on the lower inside edge to help seal against weather. The plastic is colored, weatherproof, and flexible. The flashing is preformed into several shapes adapted to cover runs, steps, corners, and cap bricks. No forming is required, only cutting to length for allow for some overlap. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of and priority to U.S. patent application Ser. No. 13/157,983 filed Jun. 10, 2011 and U.S. Provisional Application Ser. No. 61/467,831 filed Mar. 25, 2011, the entire disclosures of which are herein incorporated by reference.
FEDERAL SPONSORSHIP
[0002] Not Applicable
JOINT RESEARCH AGREEMENT
[0003] Not Applicable
TECHNICAL FIELD
[0004] This disclosure relates to mount apparatuses for photo and video cameras, including smartphones and other cameras, and more particularly, to an improved mount on a firearm for supporting the cameras.
BACKGROUND
[0005] Hunting is a popular recreational pastime in the United States and many other countries throughout the world. It has become increasingly common in recent times to record or photograph the hunt through the use of cameras and video cameras. As a result, mounting cameras and other electronic devices to a firearm in a manner that does not impede the hunt has become desired by those in the field of hunting, particularly the ability to both view the target while allowing for accurate firing of the firearm. Obtaining such a record of the hunt allows the hunter to later review his or her shots from the “eye” of the camera.
[0006] Additionally, with the advent of internet-enabled cameras, users can instantaneously email, text, or “post” pictures and videos. The devices also display images and recording before, during and after the taking of the photograph or recording. However, to be able to capture the hunt with these devices, a stand or additional person is needed, prohibiting the ability to view the hunt from the “eye” or scope of the camera. Thus, the need for such a mount to accommodate these devices has become all the more desired.
[0007] Accordingly, there is a need for an apparatus and firearm system designed to accommodate cameras and for mounting onto the scope of a firearm.
SUMMARY
[0008] The following is a summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not intended to identify key or critical elements of the invention or to delineate the scope of the invention. The sole purpose of this section is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.
[0009] Because of these and other problems in the art, described herein is an apparatus for mounting a camera onto an optical device or scope. In an embodiment, the apparatus comprises an elongated, hollow sleeve for connecting to a scope or other optical device, the sleeve having a hollow longitudinal axis forming an unobstructed axial bore; a cylindrical aperture at one end of the sleeve, the cylindrical aperture having a longitudinal axis generally coaxial with the longitudinal axis of the sleeve; a second aperture at the opposite end of the sleeve, the second aperture having a longitudinal axis generally coaxial with the longitudinal axis of the cylindrical aperture; a connector for rigidly connecting the sleeve to the scope; and a base member connected to the sleeve, the base member comprising a hole positioned adjacent to the second aperture, the base member being adapted to receive a camera having a lens having a longitudinal axis. In this embodiment, when the sleeve is connected to the scope, the cylindrical aperture is aligned with the scope and the longitudinal axis of the scope is generally coaxial with the longitudinal axis of the sleeve. Additionally, when the camera is attached to the base member, the hole of the base member is positioned adjacent to the lens of the camera and the longitudinal axis of the lens is generally coaxial with the longitudinal axis of the optical device or scope.
[0010] In one embodiment, the base member is a substantially planar plate comprising a bore or hole positioned adjacent to the second aperture. In such an embodiment, the apparatus may further comprise flanges extending substantially perpendicular from the plate of the base member. In this embodiment, the flanges are sized and shaped to secure the camera onto the base member. In such an embodiment, the apparatus may further comprise a clamp adapted to receive the camera. Additionally, the apparatus may further comprise a flange hingedly connected to the plate.
[0011] In another embodiment, the apparatus further comprises a means for securing the camera onto the base member. In yet another embodiment, the base member is removably connected to the sleeve.
[0012] In an embodiment, the connector may comprise various different configurations. For example, the connector may be an adapter connected over the scope and the sleeve, the adapter being cylindrically-shaped and hollow and the adapter having a longitudinal axis generally coaxial with the longitudinal axis of the scope and sleeve. The connector may also be an adapter secured to the scope, the adapter being cylindrically-shaped and hollow, the adapter having a longitudinal axis generally coaxial with the longitudinal axis of the scope and sleeve; wherein the sleeve is placed over the adapter, the sleeve being removably fastened to the adapter. Additionally, the connector may be a rim comprised of mirrored pieces extending substantially perpendicular from the sleeve; and a screw. In such an embodiment, the pieces of the rim are tightened with the screw to connect the sleeve to the scope.
[0013] In one embodiment of the apparatus, the sleeve is cylindrically shaped. In such an embodiment, when the sleeve is connected to the optical device or scope, the diameter of the cylindrical aperture may be equal to or greater than the outer diameter of an eyepiece of the optical device or the outer diameter of the scope.
[0014] Also disclosed herein is a device for capturing images and recordings of a firearm target, the device comprising: a firearm comprising a scope having a longitudinal axis; a camera comprising a lens having a longitudinal axis; an apparatus for mounting a camera onto a firearm, the apparatus comprising: an elongated, hollow sleeve for connecting to the scope, the sleeve having a hollow longitudinal axis forming an unobstructed axial bore; a cylindrical aperture at one end of the sleeve, the cylindrical aperture having a longitudinal axis generally coaxial with the longitudinal axis of the sleeve; a second aperture at the opposite end of the sleeve, the second aperture having a longitudinal axis generally coaxial with the longitudinal axis of the cylindrical aperture; a connector for rigidly connecting the sleeve to the scope; and a base member connected to the sleeve, the base member comprising a hole positioned adjacent to the second aperture. In such an embodiment, the sleeve is connected to the scope in such a manner that the cylindrical aperture is aligned with the scope and the longitudinal axis of the scope is generally coaxial with the longitudinal axis of the sleeve. Additionally, the camera is attached to the base member in such a manner that the hole of the base member is positioned adjacent to the lens of the camera and the longitudinal axis of the lens is generally coaxial with the longitudinal axis of the scope.
[0015] In one embodiment of the device, the base member is removably connected to the sleeve. In another embodiment, the diameter of the cylindrical aperture is equal to or greater than the diameter of the scope.
DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 provides a perspective view of an embodiment of the camera mount apparatus and system connected to the scope of a firearm.
[0017] FIG. 2 provides a side view of the embodiment of FIG. 1 .
[0018] FIG. 3 provides a top view of the embodiment of FIG. 1 .
[0019] FIG. 4 provides a perspective view of the embodiment of FIG. 1 with a smartphone secured thereto.
[0020] FIG. 5 provides a perspective view of a second embodiment of the camera mount apparatus and system with a smartphone secured thereto and connected to the scope of a firearm.
[0021] FIG. 6 provides a rear view of the embodiment of FIG. 5 .
[0022] FIG. 7 provides a front-side perspective view of the embodiment of FIG. 5 .
[0023] FIG. 8 provides a rear-side perspective view of the embodiment of FIG. 5 .
[0024] FIG. 9 provides a perspective view of a third embodiment of the camera mount apparatus and system connected to the scope of a firearm.
[0025] In accordance with common practice, it should be understood that the drawings are not necessarily to scale and that the embodiments are sometimes illustrated by graphic symbols, phantom lines, diagrammatic representations, and fragmentary views. In certain instances, details which are not necessary for an understanding of embodiments of the present invention or which render other details difficult to perceive may have been omitted. Additionally, as one of ordinary skill in the art would readily understand, the invention is not necessarily limited to the particular embodiments illustrated and described herein.
DETAILED DESCRIPTION
[0026] The present disclosure is directed to various types of mounts for securing cameras onto a scope, such as the scope of a firearm or bow. In some embodiments, the disclosure is directed to an apparatus that acts as an accessory to a conventional firearm. In other embodiments, the disclosure is directed to an actual firearm or device that is capable of and designed to store cameras. Generally, the apparatus and device are designed for connecting these cameras to the scope of the firearm while still allowing for an eye view of the target and accurate firing of the firearm viewed through the device. As a result, still photos and video recordings can be taken without a material change or effect on the firearm. As the camera is able to capture photos and video through the scope, it can also be particularly useful for training purposes, such as for a novice hunter or for military and police training.
[0027] As will become apparent upon a careful reading of the detailed description of the embodiments discussed herein, the camera mount apparatus and system for a scope provides enhanced stability, a simple means for securing the camera, and the ability to display on the camera the view seen from the scope of a weapon, such as but not limited to, a rifle or firearm. This display provides for a wider field of view and enables the shooter to zoom onto the target. Additionally, a shooter can take photos and videos before, during, and after a target has been located to be later viewed for entertainment or training. With an internet-enabled camera, the shoot can also easily stream, e-mail, text, or post the photos and videos for viewing by friends, family, and colleagues at remote locations.
[0028] “Cameras,” as used and described herein, generally relate to devices that record and store images and videos, including, but not limited to, digital cameras, camera-enabled Personal Digital Assistants, camera phones, and/or smartphones (e.g., iPhones, BlackBerrys®, Nokia N8, Motorola Droid, and the like). “Shooter,” as used and described herein, generally relates to a hunter; however, one of ordinary skill in the art would readily recognize that the embodiments disclosed herein are also very useful for other applications, including, but not limited to, military, police, security, target shooting, and any other application where a photo or recording of a shot could be utilized. “Hunt,” as used and described herein, generally relates to the practice of pursuing any living thing (usually wildlife) for food, recreation, or trade. However, the term is not intended to be limited to conventional “hunting,” and could include any use of a firearm, including, but not limited to, shooting at targets or other inanimate objects and/or chasing and potentially shooting a suspect by police or military personnel.
[0029] It should also be noted that a conventional rifle is shown as the firearm in the depicted embodiments discussed below. Those skilled in the art, however, would readily appreciate that the camera mount apparatus could be used on any firearm, including, but not limited to, long guns, shotguns, automatic rifles, assault rifles, machine guns, handguns, or the like. Additionally, the apparatus could be mounted on any device with a scope, including, for example, a bow, taser, air-soft gun, paintball gun, BB gun, or laser gun.
[0030] With reference to FIGS. 1-4 , a camera mount apparatus ( 100 ) and firearm system will be described according to a first embodiment of the present invention. The apparatus ( 100 ) includes an adapter ( 501 ) connected to the scope ( 600 ) of a firearm ( 700 ), a sleeve ( 500 ) connected the adapter ( 501 ), and a base member ( 200 ) in the form of a platform for receiving a camera ( 800 ). Both the sleeve ( 500 ) and adapter ( 501 ) are cylindrically-shaped, hollow and have longitudinal axes extending from the longitudinal axis of the scope ( 600 ) with the diameter of the sleeve ( 500 ) forming an unobstructed axial bore generally at least as wide as the diameter of the scope ( 600 ); thus, allowing for a shooter to see through the sleeve ( 500 ) and adapter ( 501 ) and into the scope ( 600 ). As shown, the adapter ( 501 ) operates as connector for connecting the scope ( 600 ) and the sleeve ( 500 ), with the adapter ( 501 ) connecting over the scope ( 600 ) and the sleeve ( 500 ). In this regard, the adapter ( 501 ) is generally made of a material that can be formed to fit securely onto both the scope ( 600 ) and the sleeve ( 500 ) without the need for additional bonding materials and while maintaining a rigidity sufficient to align the longitudinal axes of the scope ( 600 ) and sleeve ( 500 ). Examples of such a material include rubber, vulcanized rubber, polyvinyl chloride (PVC), or any other material that can be formed while maintaining a rigidity. Additionally, one of ordinary skill in the art would readily appreciate that the above examples are in no way limiting to the types of available materials. When the sleeve ( 500 ) is connected to the scope ( 600 ) in this manner, the cylindrical aperture ( 590 ) of the sleeve ( 500 ) is aligned with scope ( 600 ) and the longitudinal axis of the scope ( 600 ) is generally coaxial with the longitudinal axis of the sleeve ( 500 ).
[0031] The sleeve ( 500 ) is then connected to the adapter ( 501 ) along the same longitudinal axis as the adapter ( 501 ). The sleeve ( 500 ) is generally comprised of a rigid material, including, but not limited to PVC, metal, or the like. The base member ( 200 ) is then connected to the sleeve ( 500 ) by any means known to one of ordinary skill in the art, including, but not limited to, glue, welding or any other suitable bonding.
[0032] The base member ( 200 ) is designed to receive the camera ( 800 ) and includes a hole ( 204 ) to allow the lens of the camera to “see into” the scope ( 600 ) of the firearm ( 700 ). The base member ( 200 ) is positioned adjacent to a second aperture ( 591 ) of the sleeve ( 500 ) in such a manner that a shooter can see through the hole ( 204 ) and into the sleeve ( 500 ) and thereby into the scope ( 600 ). Stated differently, the lens extends along the longitudinal axis of the scope ( 600 ) and sleeve ( 500 ). As a result, the screen ( 801 ) of the camera ( 800 ) displays the view seen from the scope ( 600 ) of the firearm ( 700 ), as shown in FIG. 4 . In this regard, the actual design of the base member ( 200 ) can vary depending on the size, shape, and lens position of the camera, but it should be designed to sufficiently receive and secure the camera in a manner that allows the lens to see into the scope ( 600 ). In any event, the shooter advantageously would not need to put his or her eye in direct contact with the scope ( 600 ) of the firearm ( 700 ). Instead, the shooter can now view the target on the screen ( 801 ) of the camera ( 800 ) and through the scope ( 600 ). This allows for an accurate depiction of the target while also displaying a wider field of view, enabling a zoom function, and allowing the shooter to photograph or record the target and the hunt.
[0033] In an embodiment, the base member ( 200 ) includes a generally planar plate ( 201 ) with a hole ( 204 ) and flanges (( 202 ) and ( 203 )) extending therefrom and substantially perpendicular to the plate ( 201 ). The flanges (( 202 ) and ( 203 )) operate as a means for securing the camera ( 800 ) onto the plate ( 201 ). In this embodiment, a flatter camera device, such as a smartphone, will generally be used. In an alternative embodiment, however, a camera may be utilized in which the lens of the camera extends through the hole ( 204 ). The base member ( 200 ) is bonded to the sleeve ( 500 ) at approximately the location of the hole ( 204 ) of the base member ( 200 ), which, as noted above, allows for the lens to see into the scope ( 600 ). The camera ( 800 ) is placed substantially flush against the plate ( 201 ) with the lens aligned with the hole ( 204 ) and the flanges (( 202 ) and ( 203 )) securing the camera in place, as shown in FIG. 4 . Thus, the screen ( 801 ) of the camera ( 800 ) can display, photograph, and record the view seen through the scope ( 600 ). Such an arrangement is particularly advantageous as it not only allows a shooter to see the scope view on a display screen ( 801 ), but it also allows a shooter to later review photos and recordings from the actual view of the scope.
[0034] In an embodiment, one flange ( 202 ) is at the top of the plate ( 201 ) and one flange ( 203 ) is at the bottom of the plate ( 201 ). This arrangement is by no means necessary, as one of ordinary skill in the art would readily recognize that the flanges could also or alternatively be placed on the sides of the plate ( 201 ) and could include any number of flanges. These flanges (( 202 ) and ( 203 )) additionally have rounded corners (( 205 )-( 208 )) as a further means for securing the particular camera ( 800 ) in place. Again, this particular design of the flanges is by no means necessary, as one of skill in the art would readily recognize that other arrangements and designs of flanges could similarly be used to secure the camera in place. For example, the flanges could be bendable such that once the device is placed against the plate, the flanges could be bent inward to secure the camera into place. The edges of the flanges may also be slightly indented in order to receive and secure the camera. In the depicted embodiments, the flanges (( 202 ) and ( 203 )) are sized and shaped such that the camera ( 800 ) can securely snap into place. To remove the camera ( 800 ) from the base member ( 201 ), a shooter can simply snap the camera ( 800 ) out of place. It should also be noted that the means for securing the camera ( 800 ) in place is not limited to the flanges, as one of ordinary skill in the art would readily appreciate, and could include, for example, adhesives, bands, clamps, contoured cases, fasteners, or the like.
[0035] In certain embodiments, the apparatus ( 100 ) also may include a stabilizer ( 250 ). One of ordinary skill in the art would readily appreciate that this stabilizer ( 250 ) is by no means necessary as the apparatus ( 100 ) in FIGS. 1-4 may merely be comprised of the base member ( 200 ) and a means for connecting the base member to the scope, which provides all the benefits described above. In fact, in many embodiments, the stabilizer ( 250 ) may not be feasible, for example, if the firearm ( 700 ) in FIGS. 1-4 did not have a stock ( 701 ), or as shown in FIGS. 5-9 and described below.
[0036] However, for certain embodiments and with certain types of firearms, a stabilizer ( 250 ) advantageously helps secure the camera ( 800 ) onto the plate ( 201 ) of the base member ( 200 ). The stabilizer ( 250 ) generally includes an adjustable top clamp ( 252 ) and adjustable bottom clamp ( 251 ) both connected to a back panel ( 254 ) with a receiving nut ( 253 ), a screw ( 400 ) attached to an adjuster ( 302 ) for threading into the receiving nut ( 253 ), and a support ( 301 ) attached to the adjuster ( 302 ) for securing the stabilizer ( 250 ) onto the firearm ( 700 ). In an embodiment, the support ( 301 ) is attached to the stock ( 701 ) of the firearm ( 700 ). The support ( 301 ) can be attached by any sufficient means for securing the support ( 301 ). In the depicted embodiment, the support ( 301 ) is attached with a bolt ( 311 ) and washer ( 310 ) and secured with a nut ( 312 ). This type of fastening, however, is by no means the only available fastening as one of ordinary skill in the art would readily appreciate.
[0037] The clamps (( 252 ) and ( 251 )) are movably and adjustably connected to the back panel ( 254 ). As noted above, the back panel ( 254 ) also includes a receiving nut ( 253 ). As discussed more below, when the receiving nut ( 253 ) is loosened, the clamps (( 252 ) and ( 251 )) can be adjusted by sliding the clamps along the vertical axis of the back panel ( 254 ). This allows the clamps (( 252 ) and ( 254 )) to be tightened once the camera ( 800 ) is in place.
[0038] The adjuster ( 302 ) includes a ball-bearing ( 304 ) there within and a thumbscrew ( 303 ) which serves to thread the screw ( 400 ) to tighten and loosen the receiving nut ( 253 ) such that the adjustable top clamp ( 252 ) and adjustable bottom clamp ( 251 ) can be moved up and down along the vertical axis of the back panel ( 254 ) to help secure the camera ( 800 ) in place. In other words, when the thumbscrew ( 303 ) is loosened, the clamps (( 252 ) and ( 251 )) can easily slide and be adjusted. Thus, a shooter can loosen the thumbscrew ( 303 ), snap the camera ( 800 ) on the plate ( 201 ), adjust the clamps (( 252 ) and ( 251 )) into place, and then tighten the thumbscrew ( 303 ) in order to secure the camera ( 800 ) into place with the now tightened clamps (( 252 ) and ( 251 )). To remove the camera ( 800 ), the shooter simply unscrews the thumbscrew ( 303 ), slides the clamps (( 252 ) and ( 251 )), and snaps the camera out of the base member ( 200 ).
[0039] As similarly described above, it is important to note, as one of ordinary skill in the art would readily appreciate, the stabilizer (including the clamps, back panel, receiving nut, screw, adjuster, and support) is by no means necessary.
[0040] Turning now to FIGS. 5-8 , a camera mount apparatus ( 2100 ) and firearm system will be described according to an embodiment of the present invention. This embodiment is similar to the embodiment discussed above in reference to FIGS. 1-4 in that the apparatus ( 2100 ) connects to the scope ( 2600 ) of a firearm ( 2700 ) to allow a camera ( 2800 ) to display, photograph, and/or record the view seen from the scope ( 2600 ). In this embodiment, however, the stabilizer is omitted. Additionally, this embodiment includes other means for securing the apparatus ( 2100 ) to the scope ( 2600 ) and for securing the camera ( 2800 ) to the apparatus ( 2100 ), among other differences discussed more fully below.
[0041] The apparatus ( 2100 ) includes a sleeve ( 2500 ) connected to the scope ( 2600 ) by means of an adapter ( 2501 ) and a base member ( 2200 ) in the form of a platform for receiving an camera ( 2800 ) with the base member ( 2200 ) removably connected to sleeve ( 2500 ) by means of a receiver ( 2504 ). The sleeve ( 2500 ) and adapter ( 2501 ) are cylindrically-shaped, hollow and have longitudinal axes extending from the longitudinal axis of the scope ( 2600 ) with the diameter of the sleeve ( 2500 ) forming an unobstructed axial bore generally at least as wide as the diameter of the scope ( 2600 ); thus, allowing for a shooter to see through the sleeve ( 2500 ) and adapter ( 2501 ) and into the scope ( 2600 ). These components are connected in such a manner that that the apparatus ( 2100 ) can be attached easily to scopes of varying sizes. Additionally, as the base member ( 2200 ) is removably connected, different types and sizes of base members can be utilized and changed with ease. As a result, a user can seamlessly remove and change the base member ( 2200 ) to secure the camera of choice.
[0042] As shown, the adapter ( 2501 ) operates as a connector for connecting the sleeve ( 2500 ) to the scope ( 2600 ), with the sleeve ( 2500 ) securely connecting over the top of the adapter ( 2501 ) and along the same longitudinal axis as the adapter ( 2501 ). The sleeve ( 2500 ) is secured to the adapter ( 2501 ) with screw fasteners ( 2503 ), which further operate as a means for connecting the sleeve ( 2500 ) to the scope ( 2600 ). When the sleeve ( 2500 ) is connected to the scope ( 2600 ) in this manner, the cylindrical aperture ( 2590 ) of the sleeve ( 2500 ) is aligned with scope ( 2600 ) and the longitudinal axis of the scope ( 2600 ) is generally coaxial with the longitudinal axis of the sleeve ( 2500 ). The receiver ( 2504 ) is similarly connected to the sleeve ( 2500 ) with screw fasteners ( 2505 ) and along the same longitudinal axis. The receiver ( 2504 ), however, is by no means necessary. For example, the base member ( 2200 ) could alternatively be directly and removably connected to the sleeve ( 2500 ).
[0043] The sleeve ( 2500 ), adapter ( 2501 ), and receiver ( 2504 ) are generally comprised of a rigid material, including, but not limited to PVC, metal, or the like. The base member ( 2200 ) is then removably connected to the receiver ( 2504 ). As noted above, this removable connecting mechanism allows varying sizes and types of base members, and thereby varying sizes and types of cameras, to be utilized with the apparatus. For example, a base member may have a hole in the center to be used in conjunction with an camera with a similarly central lens.
[0044] The base member ( 2200 ) is designed to receive the camera ( 2800 ) and includes a hole to allow the lens of the camera to “see into” the scope ( 2600 ) of the firearm ( 2700 ). The base member ( 2200 ) is connected to the receiver ( 2504 ), and thereby positioned adjacent to a second aperture ( 2591 ) of the sleeve ( 2500 ), in such a manner that a shooter can see through the hole and into the receiver ( 2504 ), sleeve ( 2500 ), and adapter ( 2501 ), and thereby into the scope ( 2600 ). Stated differently, the lens extends along the longitudinal axis of the scope ( 2600 ) and sleeve ( 2500 ). As a result, the screen ( 2801 ) of the camera ( 2800 ) displays the view seen from the scope ( 2600 ) of the firearm ( 2700 ), as shown in FIG. 5 . In this regard, and as noted above, the actual design of the base member ( 2200 ) and the position of the hole can vary depending on the size, shape, and lens position of the camera, but it should be designed to sufficiently receive and removably secure the camera in a manner that allows the lens to see into the scope ( 2600 ). In any event, the shooter advantageously would not need to put his or her eye in direct contact with the scope ( 2600 ) of the firearm ( 2700 ) with the apparatus ( 2200 ) of the present disclosure. Instead, the shooter can now view the target on the screen ( 2801 ) of the camera ( 2800 ) and through the scope ( 2600 ). This allows for an accurate depiction of the target while also displaying a wider field of view, enabling a zoom function, allowing the shooter to photograph or record the target and the hunt.
[0045] In an embodiment, the base member ( 2200 ) includes a generally planar plate ( 2201 ) with a hole, flanges (( 2205 ) and ( 2206 )) extending from the top end of the plate ( 2201 ) and substantially perpendicular to the plate ( 2201 ), the flanges (( 2205 ) and ( 2206 )) comprising rounded corners, and a clamp ( 2210 ). The flanges (( 2205 ) and ( 2206 )) and clamp ( 2210 ) operate as a means for securing the camera ( 2800 ) onto the plate ( 2201 ). The base member ( 2200 ) is connected to the receiver ( 2204 ) at approximately the location of the hole of the base member ( 2200 ), which, as noted above, allows for the lens to see into the scope ( 2600 ). The camera ( 2800 ) is placed substantially flush against the plate ( 2201 ) with the lens aligned with the hole and the rounded corners of the flanges (( 2205 ) and ( 2206 )) and the clamp ( 2210 ) all securing the camera in place, as shown in FIGS. 5-6 . In this regard, the clamp ( 2210 ) is generally adjustable or bendable and is adapted to receive and help secure the camera ( 2800 ) in place. Thus, with this arrangement, and as noted above, the screen ( 2801 ) of the camera ( 2800 ) can display, photograph, and record the view seen through the scope ( 2600 ), and additionally, this arrangement advantageously not only allows a shooter to see the scope view on a display screen ( 2801 ), but it also allows a shooter to later review photos and recordings from the actual view of the scope.
[0046] In the depicted embodiments, the flanges (( 2202 ) and ( 2203 )) are sized and shaped such that the camera ( 2800 ) fits into place on the plate ( 2201 ). As noted above, in this embodiment, the flanges (( 2202 ) and ( 2203 )) are in the shape of rounded corners. To remove the camera ( 2800 ) from the base member ( 2201 ), a shooter can simply bend or adjust the clamp ( 2210 ) and slide the camera ( 2800 ) out of place. This particular design of the flanges and clamp is by no means necessary, as one of skill in the art would readily recognize that other arrangements and designs of flanges could similarly be used to secure the camera in place. For example, the flanges also could be bendable such that once the device is placed against the plate, the flanges could be bent inward to secure the camera into place. The edges of the flanges may also be slightly indented in order to receive and secure the camera. It should also be noted that the means for securing the camera in place is not limited to the flanges, as one of ordinary skill in the art would readily appreciate, and could include, for example, adhesives, bands, clamps, contoured cases, fasteners, or the like.
[0047] Turning now to FIG. 9 , a camera mount apparatus ( 1000 ) and firearm system will be described according to another embodiment of the present invention. This embodiment is similar to the embodiments discussed above in reference to FIGS. 1-8 in that the apparatus ( 1000 ) connects to the scope ( 1600 ) of a firearm ( 1700 ) to allow an camera ( 1800 ) to display, photograph, and/or record the view seen from the scope ( 1600 ). In this embodiment, however, the stabilizer and the adapter are omitted and a hinged flange ( 1206 ) is included as a means for securing the camera ( 1800 ), among other differences. The apparatus ( 1000 ) includes a base member ( 1200 ) with an insertion tube ( 1209 ) connected directly to the sleeve ( 1500 ), which is in turn connected to the scope ( 1600 ) of a firearm ( 1700 ). Again the sleeve ( 1500 ) is cylindrically shaped, hollow and has a longitudinal axis extending from the longitudinal axis of the scope ( 1600 ); thus, allowing for a shooter to see through the sleeve ( 1500 ) and into the scope ( 1600 ).
[0048] As shown, the sleeve ( 1500 ) is adjustably connected over the scope ( 1600 ) and insertion tube ( 1209 ) of the base member ( 1200 ). In this regard, the sleeve ( 1500 ) will generally contain a tightening mechanism to secure both the sleeve ( 1500 ) onto the scope ( 1600 ) and the insertion tube ( 1209 ) of the base member ( 1200 ) onto the sleeve ( 1500 ). In the depicted embodiments, the sleeve ( 1500 ) includes rims ( 1503 ) comprised of two mirrored pieces extending substantially perpendicular from the sleeve ( 1500 ) with the rims ( 1503 ) operating as a connector for connecting the sleeve ( 1500 ) to both the scope ( 1600 ) and the base member ( 1200 ). Thus, the sleeve ( 1500 ) can be placed over the scope ( 1600 ) on one end and then over the insertion tube ( 1209 ) of the base member ( 1200 ) on the other end. The pieces of the rims ( 1503 ) are then pinched together and tightened with screws ( 1502 ) to secure the base member ( 1200 ) onto the sleeve ( 1500 ) and thereby onto the scope ( 1600 ). When the sleeve ( 1500 ) is connected to the scope ( 1600 ) in this manner, the cylindrical aperture ( 1590 ) of the sleeve ( 1500 ) is aligned with the scope ( 1600 ) and the longitudinal axis of the scope ( 1600 ) is generally coaxial with the longitudinal axis of the sleeve ( 1500 ). The sleeve ( 1500 ) and rims ( 1503 ) are generally comprised of a rigid material, including, but not limited to PVC, metal, or the like.
[0049] The base member ( 1200 ) is designed to receive the camera ( 1800 ) and includes a bore or hole ( 1204 ) to allow the lens of the camera to “see into” the optical device or scope ( 1600 ) of the firearm ( 1700 ) and includes an insertion tube ( 1209 ). The insertion tube ( 1209 ) of the base member ( 1200 ) is secured to the sleeve ( 1500 ) at the second aperture ( 1591 ) of the sleeve ( 1500 ), as discussed above, and in such a manner that a shooter can see through the hole ( 1204 ) and into the sleeve ( 1500 ) and thereby into the scope ( 1600 ). Stated differently, the lens extends along the longitudinal axis of the scope ( 1600 ) and sleeve ( 1500 ). As a result, the screen ( 1801 ) of the camera ( 1800 ) displays the view seen from the scope ( 600 ) of the firearm ( 700 ), as similarly discussed above. Again, as similarly discussed above in reference to FIGS. 1-9 , the actual design of the base member ( 1200 ) can vary depending on the size, shape, and lens position of the camera, but it should be designed to sufficiently receive and secure the camera in a manner that allows the lens to see into the scope ( 1600 ). In any event, the shooter advantageously would not need to put his or her eye in direct contact with the scope ( 1600 ) of the firearm ( 1700 ). Instead, the shooter can now view the target on the screen ( 1801 ) of the camera ( 1800 ) and through the scope ( 1600 ). This allows for an accurate depiction of the target while also displaying a wider field of view, enabling a zoom function, and allowing the shooter to photograph or record the target and the hunt.
[0050] In an embodiment, the base member ( 1200 ) includes a generally planar plate ( 1201 ) with a bore or hole ( 1204 ), flanges (( 1202 ), ( 1203 ) and ( 1205 )) extending therefrom and substantially perpendicular to the plate ( 1201 ), and a hinged flange ( 1206 ) hingedly connected to the plate ( 1201 ) for securing the camera ( 1800 ) in place. The base member ( 1200 ) is connected to the sleeve ( 1500 ) at approximately the location of the hole ( 1204 ) of the base member ( 1200 ), which, as noted above, allows for the lens to see into the scope ( 1600 ). The hinged flange ( 1206 ) is hinged open and the camera ( 1800 ) is slid onto the plate ( 1201 ) with the lens aligned with the hole ( 1204 ) and the flanges (( 1202 ), ( 1203 ) and ( 1205 )) securing the camera in place. The hinged flange ( 1206 ) is then locked into place to secure the camera in place. In this regard, the hinged flange ( 1206 ) includes a tab ( 1207 ) which snaps easily on and off the receiver ( 1208 ) connected to the top flange ( 1202 ). Once in place, the screen ( 1801 ) of the camera ( 1800 ) can display, photograph, and record the view seen through the scope ( 1600 ). Such an arrangement is particularly advantageous as it not only allows a shooter to see the scope view on a display screen ( 1801 ), but it also allows a shooter to later review photos and recordings from the actual view of the scope.
[0051] In an embodiment, the top flange ( 1202 ) is at the top of the plate ( 1201 ), the bottom flange ( 1203 ) is at the bottom of the plate ( 1201 ), and the side flange ( 1205 ) and hinged flanged ( 1206 ) are at the sides of the plate ( 1201 ). This arrangement is by no means necessary, as one of ordinary skill in the art would readily recognize that the flanges could alternatively include any number of flanges and the hinged flange ( 1206 ) could be located on either side, the top, or the bottom of the plate ( 1201 ). Additionally, these flanges (( 1202 ), ( 1203 ) and ( 1205 )) are in the shape of an “L” to help secure the particular camera ( 1800 ) in place. Again, this particular design of the flanges is by no means necessary, as one of skill in the art would readily recognize that other arrangements and designs of flanges could similarly be used to secure the camera in place. For example, the flanges could be bendable such that once the device is placed against the plate, the flanges could be bent to secure the camera into place, or the edges of the flanges may also be slightly indented in order to receive and secure the camera. In the depicted embodiments, the flanges (( 1202 ), ( 1203 ) and ( 1205 )) are sized and shaped in the form of an “L” such that the camera ( 1800 ) can securely slide into place. To remove the camera ( 1800 ) from the base member ( 1201 ), a shooter can simply slide the camera ( 1800 ) out of place.
[0052] While the invention has been disclosed in conjunction with a description of certain embodiments, including those that are currently believed to be the preferred embodiments, the detailed description is intended to be illustrative and should not be understood to limit the scope of the present disclosure. As would be understood by one of ordinary skill in the art, embodiments other than those described in detail herein are encompassed by the present invention. Modifications and variations of the described embodiments may be made without departing from the spirit and scope of the invention. | This disclosure relates to an apparatus for mounting a camera onto a firearm and an associated device for capturing images and recordings of a firearm target. The apparatus allows for easy attachment of cameras of varying sizes onto the scope of a firearm and along the same longitudinal axis of the scope. The apparatus comprises a sleeve connected to a scope of a firearm, the sleeve being hallow and having a longitudinal axis longitudinal axis forming an unobstructed axial bore and generally coaxial with a longitudinal axis of the scope; a base member with a hole and adapted to receive a camera with the hole of the base member positioned adjacent to the lens of the camera and the longitudinal axis of the camera lens is generally coaxial with the longitudinal axis of the scope. | 5 |
BACKGROUND AND SUMMARY
[0001] Electrical components are designed to operate at particular levels of voltage, current draw, and other monitorable characteristics. For example, servo systems are designed to run at a set velocity, which is monitored via an encoder mounted on the servo. If the servo operates above or below the set point, the servo controls can detect the aberrant behavior of the servo by, for example, sensing a corresponding deviation in encoder frequency and attempt to correct for the encoder frequency error. If the error is easily corrected by the system, the correction takes place and the servo continues to function. However, if the error in encoder frequency (velocity) begins to exceed certain limits, the control system will determine that it can no longer operate within specification. When this occurs, the controller typically disables the servo motor drive and issues an alert, such as, for example, a numerical code, to the main control system. This alert tells the main controller that the servo is no longer operating and that a fault has been declared.
[0002] The above sequence is a typical shutdown technique and reveals to the main control system that a servo hardware fault has occurred. No other information is passed on for evaluation to the tech rep or the customer. The problem that caused the error could well have been the motor hardware or could have been the load that is driven by the servo motor. If the problem is a marginal situation in either the load or the motor, determining the root cause could be difficult since faults might be intermittent. Also, there is no information stored in the system that could give a historical account of encoder frequency excursions that did not cause a shutdown. A history of encoder frequency values that shows poor behavior would be useful to service personnel, and there is thus a need for such a history. Tech reps or design engineers could use such a history to determine that, over a specified operating period, the frequency of the servo motor's deviations and the amplitude by which the motor had deviated from its set point.
[0003] An onboard microprocessor can selectively monitor a component, such as a motor or a solenoid, by selectively sensing current used by the component. While supplying sensors for each component of a system is not practical with current technology, embodiments sense the current supplied to a group of components when only one of the components is operating. The sensed current can be compared to a reference current indicative of proper component operation, and the result of the comparison can be recorded. If there is a discrepancy, then the component is likely defective and should be serviced. Recording the result can include storing the result in a computer memory, displaying an alert when there is a discrepancy between the reference current and the current supplied to the group of components, and/or recording the circuit to which current was supplied during sensing. Additionally, embodiments can allow access to the recorded result via a computer network, an on-board display, and/or a computer connected to a direct-connect port, such as a serial port. Using recursion, embodiments can be used to detect groups of components or subsystems that are having trouble, groups of components or subsystems within those groups or subsystems, etc., until a particular aberrant component is identified.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] [0004]FIG. 1 shows a schematic of a machine in which embodiments can be employed.
[0005] [0005]FIG. 2 shows a schematic of systems of a machine in which embodiments might be employed.
[0006] [0006]FIG. 3 shows a schematic of a portion of a machine to which embodiments can be applied and the components such a machine can include.
[0007] [0007]FIG. 4 shows a schematic chart illustrating a method that can be executed in embodiments of the invention.
DETAILED DESCRIPTION
[0008] While this specification describes a technique that can identify an aberrant component, this is simply exemplary and one of ordinary skill in the art should realize that the technique can be applied to aberrant systems and groups of components without departing from the scope of the invention and recursively with whatever resolution might be appropriate for a particular application.
[0009] Embodiments can be employed in a printing machine 1 , such as that shown in FIG. 1. Such printing machines typically include at least one main controller 10 , as the controllers seen schematically, for example, in FIG. 2, that can, among other things, control a servo motor 20 , as does the paper path controller 10 , that can include a servo encoder 21 . Such a main controller 10 typically includes at least one microprocessor 30 , which will often include on-board random access memory (RAM) 31 or the like and/or can have access to expanded RAM 32 or the like. The microprocessor 30 can also be part of a microcontroller 40 that itself can include onboard RAM 41 or the like and/or can have access to expanded RAM 42 or the like.
[0010] The onboard microprocessor 30 , in embodiments, selectively monitors a group of components 20 that includes a component 21 , such as a motor, by sensing a characteristic of the component, such as current drawn by the group 20 . For example, to determine whether the component 21 were operating properly, the microprocessor 30 would sense current drawn by the group 20 when the component 21 was the only component operating. The onboard microprocessor 30 would compare the current drawn by the group 20 to a reference current value indicative of proper operation and store the results in a memory, such as a RAM 31 , 32 , of the microprocessor. The data can remain in the memory for later retrieval or can be uploaded to another location, such as a main controller 10 or to non-volatile memory, such as a hard drive. The uploads can be continuous or at intervals. The system can be configured so that only those values outside of normal limits would be stored for analysis.
[0011] Advantageously, embodiments can recursively employ this technique to monitor systems, subsystems, and subgroupings within subsystems on down to individual components, depending on the particular configuration of the machine 1 in which embodiments are employed and the particular resolution desired. As illustrated in
[0012] In embodiments in which more components are monitored, more RAM 31 , 32 , 41 , 42 can be necessary and more processing time can be required. Thus, in such embodiments, the microprocessor 30 should be relatively fast and have RAM 31 , 32 available internally or externally for the storage. For example, the microprocessor 30 could be an Intel P89C51RB2 with 256 bytes RAM and 256 bytes Flash on board, or the microprocessor 30 could be of another type with external RAM chips for the micro's use. Additionally, a microcontroller 40 with 1 kB of internal RAM could be used in the six cycle clock mode. Running in this mode essentially doubles the internal speed of the controller's 40 processing capabilities. Therefore, for example, a P89C51RD2 (with 1 KB internal RAM 41 ) by Intel could be used that would run at twice the normal speed. This would be more than enough to handle the required processing. Additionally, for example, standard, off-the-shelf external RAM integrated circuits 42 could be used to augment data storage. Any amount of external RAM 42 would then be placed on the board that would meet the required storage needs.
[0013] More real time would be needed to hand data from the target micro 30 , 40 to the main controller 10 . Also, traffic on the serial bus system 11 would increase in order to get the data across. The main control unit 10 would be responsible for decisions about the health of the system according to its analysis, which would require additional real time from the main unit 10 .
[0014] The system main controller 10 can thus obtain a history of aberrant component events, such as aberrant motor encoder events, or could even obtain histories of multiple components, subsystems, and systems in the machine. The main controller 10 could then make decisions about machine operation that could be communicated to, for example, service personnel. When a predetermined threshold of events is reached, for example, the machine diagnostics could alert service that a failure is eminent. Further, service could access this data, locally or remotely, and determine if further repairs are needed. The information obtained from the system could be used to determine the cause of an intermittent problem.
[0015] A schematic illustration of a method executed in embodiments is shown in FIG. 4. The method can start, block 101 , and select and isolate a first component or group of components, block 102 . The selection and isolation can start with a default component or group of components to test, such as might be stored in a RAM 31 or ROM of the controller 10 . Once the component or from to be tested has been selected, current is sensed, block 103 . A reference current is retrieved for the component or group being tested, block 104 , which reference current can, for example, be stored in RAM 31 or ROM of the controller, or on a hard disk in communication with the controller. The sensed current and reference current are compared, block 105 , and if the sensed current is acceptable, a satisfactory result can be recorded, block 106 , the next component or group is identified, block 107 , and the method can return to block 102 . If the sensed current is not acceptable, then a fault is recorded, block 108 , an alert can be initiated, block 109 , and/or a record can be transmitted via a connected network, block 110 . If the fault was in a group, block 111 , then the next level of detail within that group can be resolved for testing, block 113 , the next component or group is identified, block 107 , and testing can continue from block 102 . If the fault was in a component, then, if any remain, the next component or group of components can be identified, block 112 , and testing can continue from block 102 . If there are no more components or groups to be tested, then testing can stop, block 114 .
[0016] While embodiments have been described in the context of monitoring a motor encoder 21 , those of ordinary skill in the art should recognize that other components could be monitored using the method and apparatus described above. For example, this technique can be used on other applications such as sensor readings, power supply voltage readings, timing functions, and the recording of pulse width modulation (PWM) values. Data can be kept on almost any application that could help machine diagnostics. It could be accomplished at the firmware level as with the motor encoder and the data could be analyzed there or at the main control. Sensor pullin/pullout times and electromechanical clutch pullin/pullout times can be treated in the same manner. Power supply voltages can be monitored and any deviations be placed into their own histograms. Any device using PWM control would fit the algorithms of this technique. The histograms of all of these items, including paper path timing, could be stored on the microcontroller or microprocessor and read by the main control board or a remote computer at some convenient time. Further, the method can be applied recursively to test an entire machine's systems and subsystems.
[0017] Other modifications of the present invention may occur to those skilled in the art subsequent to a review of the present application, and these modifications, including equivalents thereof, are intended to be included within the scope of the present invention. | Current supplied to a group of components is selectively sensed so that the current supplied when a particular component is the only active component can be compared to a reference current indicative of proper component operation. If there is a discrepancy, an alert can be generated. Can be applied on a larger scale to allow isolation of a subsystem, then a group within the subsystem, then a component with the group, etc. | 6 |
FIELD OF THE INVENTION
[0001] This application relates in general to optical communication, and in specific to an assembly for an MSM photodetector.
BACKGROUND OF THE INVENTION
[0002] Optical fiber technology is well suited for communications applications because optical fibers have a wide transmission bandwidth and relatively low attenuation. However, optical fiber interfaces to electronic and optical networks are expensive to manufacture because of the difficulty associated with mounting laser transmitting and receiving devices onto substrates and aligning them with separately mounted optical fibers. The difficulties generally are associated with manufacturing components with precise tolerances and mounting components at precise locations within precise tolerances. The challenges of alignment are typically faced during the packaging of the devices. To overcome these difficulties, the transmitter and receiver devices can be enlarged so as to alleviate the tight tolerances that are difficult to achieve during alignment.
[0003] In a conventional optical fiber communications system, a transmitter sends optical data into a fiber, and the data is received by a detector at the receiving end. Two inherent interfaces exist at both ends of the fiber. Minimizing the optical loss at these two interfaces is difficult due to the alignment at the micron scale. Alleviating the alignment tolerance at the transmission end can be done by enlarging the core of the optical fiber. However, this has an undesirable effect at the receiving end interface. Namely, the light that exits a larger core fiber has a larger cross-sectional area, thereby making it difficult to capture the light.
[0004] Large core fibers, e.g. fibers with core diameters of 50 to 63 microns, are typically found in local area network (LAN) environments. The large cores provide more tolerances for installation than smaller core fibers, e.g. coupling the fiber to a source laser or a receiving photodetector, as well as coupling fibers together with an optical connector. Two types of photodetectors are typically used to receive the light from the fiber and convert the light into an electrical signal, namely a PN diode and a metal semiconductor metal (MSM) diode. Both are currently made to be about 70 to 80 microns in diameter, so as to capture the light from the LAN fibers.
[0005] Another type of fiber is being used in limited applications, namely the hard clad silica fiber (HCS) fiber. This fiber has a silicon core surrounded by a hard plastic cladding and has diameters of typically 200-300 microns.
[0006] A further type of fiber is a plastic fiber. This fiber is similar to the HCS fiber, but uses a plastic core instead of a silica core. Since the core is plastic, the attenuation of the fiber limits effective use of the fiber to distances of 10 meters or less.
[0007] Accordingly, there is a need for an optical receiving assembly that incorporates all the necessary optical and electrical components to capture the light exiting the large area fiber of a low cost platform.
BRIEF SUMMARY OF THE INVENTION
[0008] Embodiments of the present invention are directed to a system and method which is associated with an optical-to-electrical signal conversion device used for receiving data in communications. Embodiments of the invention are particularly low cost in packaging due to their formation in a resin molded leadframe with integrated optical and electrical components. Embodiments of the invention use a large, high speed photodetector with a large diameter fiber.
[0009] According to the present invention, a large area metal-semiconductor-metal (MSM) photodetector(s) is used to capture the light exiting a large optical fiber inside a connectorized package assembly. The inventive MSM photodetector can receive a single optical channel using a single detector or multiple optical channels using an array of detectors. The MSM photodetector converts the optical signal into electrical signal, in each respective channel. The electrical signal is amplified via an integrated circuit chip or a separate discrete chip inside the same package.
[0010] In one embodiment of the present invention, a single or array of fibers is held in place by an external connector. The external connector positions the fibers perpendicular or parallel to the detector surface. Alignment for coupling into the detector is done by the mating of the connector to the assembly. In the perpendicular configuration, the fibers allow the exiting light to be captured with or without focusing elements. In the parallel configuration, the connector reflects the light in an angle that allows the capturing of the light. The reflecting surface in the connector may or may not contain a focusing element. According to another embodiment of the present invention, a substrate is provided for mating optical components with an optical connector body.
[0011] Embodiments of the invention use a large optical fiber of 100 microns or greater, e.g. 100, 200, or 400 microns, that may be an HCS fiber or a plastic fiber. The MSM photodetector would be appropriately sized for the fiber. Embodiments of the invention may include a lens to focus the light onto the detector. This would allow a detector that is smaller than the diameter of the fiber. Embodiments of the invention have the photodetector mounted an a substrate, e.g. a printed circuit board, a lead frame substrate, a RF ceramic substrate, or a silicon substrate.
[0012] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawing, in which:
[0014] FIG. 1 is a schematic of an optical system using an embodiment of the invention;
[0015] FIG. 2 is a schematic of an example of a connector and photodetector according to embodiments of the invention;
[0016] FIG. 3 is a schematic of another example of a connector and photodetector according to embodiments of the invention; and
[0017] FIG. 4 is a graph comparing MSM photodetectors and a pin photodiode.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Embodiments of the invention would operate in situations that need short, high speed optical data links, e.g. 30 meters or less. For example, embodiments of the inventor could be used in entertainment systems, computer systems, automotive systems, transportation systems, storage systems, industrial systems, aviation systems, multimedia systems, information technology systems, etc. For example, embodiments of the invention could link two computer systems together, connect a DVD player to a TV (which may be located in a building, car, train, airplane, or other transportation system), connect a tuner/control unit to a large panel TV monitor, link a game controller to a game box, connect a house hold appliance (e.g. a TV, stereo, telephone, computer, camera, etc.) to a control system, connect a digital camera to storage or control system or a display screen, connect a sensor to a computer, connect a control mechanism to a computer, connect a computer to a projector or monitor, or connect devices to a multiplexer or demultiplexer. Furthermore, embodiments of the invention may be used with large screen devices like high definition TV (HDTV) sets that use high speed connections to the control unit.
[0019] FIG. 1 depicts an arrangement for an optical communications system 100 using an embodiment of the invention. The system 100 includes an optical fiber 101 that has a core diameter of 100 microns or larger, e.g. 100, 200, 400, 800, 1000 microns, or 100-1000 microns. The fiber may be a plastic optical fiber (POF) or a HCS fiber. The core of the fiber 102 would carry the optical light signal. The system may include one fiber or a plurality of fibers. Note that the large fiber diameter is desired, because it allows for higher installation tolerances. In other words, the larger the diameter, the looser the alignment tolerance on coupling, which allows for a cheaper coupling to be used.
[0020] System 100 uses transmitter 103 to generate and couple the light used for the signal into the fiber. The transmitter 103 would form modulated light which is then coupled into this optical fiber. This light would carry information through the fiber 101 in the form of light pulses. The light may be formed by laser 108 , which may a diode laser, in the form of a Fabry-Perot (FP) laser, or a vertical-cavity surface-emitting laser VCSEL. The light source could also be a high speed light emitting diode (LED). Typically, the light generated will have a wavelength from 500-1550 nanometers. Most systems will operate at around 650 nm, 780 nm, or 850 nm wavelengths.
[0021] The light pulses would be detected by the receiver 104 . The receiver 104 is coupled to the fiber 101 with an optical connector 105 . For some applications the connector might be omitted, and the fiber would be permanently attached to the photodiode. The receiver includes photodetector 106 , which may be an MSM photodetector. The photodetector would then convert the light signal into an electrical signal. The electrical signal may then be sent to another receiver component 109 , e.g. an amplifier, filter, and/or other processing component, and/or the signal is (then) sent to off-receiver component 110 , which may be an amplifier, filter, and/or other processing element, including a transmitter for another fiber. The photodetector would be sized as appropriate for the fiber, e.g. for a 100 micron fiber, the photodetector would be either 100 microns or slightly larger.
[0022] Optionally, the receiver 104 may include lens 107 which would focus the light onto the photodetector. This would allow the photodetector to be smaller than the fiber diameter and still receive all of the light from the fiber. However, there is a limit as to the reduction in size that is possible with using a lens. The phase space product of the light needs to be conserved, which means that the product of the numerical aperture of the fiber times the area of the fiber has to be a constant. Thus, to shrink the area of the photodetector, the numerical aperture of the light shining onto the photodetector needs to be increased, which has a fundamental limit of 1. Therefore, the light out of the fiber cannot be focused down to a single spot. A reduction of 50% might be feasible with carefully designed optics.
[0023] An MSM photodetector is preferably over a p-intrinsic-n (PIN) photodetector. As the size of a PIN-type photodetector is increased, the capacitance is increased, effectively lowering the bandwidth or speed of the system. Thus, for speeds of more than 1 gigabit per second, the typical diameter of a PIN photodetector would have to be less than 100 micrometers. Because of the geometrical configuration of the MSM photodetector, it has much lower capacitance than a PIN photodetector of the same size. Thus, the MSM photodetector may be larger than 100 micrometers and still allow for speeds in excess of 1 gigabit per second.
[0024] The graph 400 in FIG. 4 shows a comparison of the calculated time constants of two MSM photodetectors with an electrode spacing of 2 μm ( 401 ) and 3 μm ( 402 ) respectively, and a pin photodiode ( 403 ) with an absorbing layer thickness of 2 μm. Note that the MSM detector is significantly faster for diameters of 150 μm and above. For smaller diameters the drift time is more dominant, and therefore, the speed of the pin-diode is comparable with the MSM detector.
[0025] An MSM photodetector may comprise gallium arsenide that is basically undoped. Typical metal for the electrodes may be platinum with a gold layer on top A titanium layer beneath improves the adhesion to the semiconductor. Thicknesses of the titanium would be in the range of 20 nanometers, the platinum would be typically 100 to 200 nanometers and the gold layer typically would be another 200 nanometers to 1 micron. The purpose of the electrodes is to collect the carriers generated in the semiconductor. The electrodes also form a Schottky barrier to the semiconductor. The width of the electrodes would be as small as possible in order to have the least amount of light blocking. The typical width of these electrodes is in the range of 1 micron or lower, e.g. 0.7 microns. The space in between the two electrodes on the top surface would need to be optimized for the specific application of the photodetector. The longer the distance the more voltage is needed to operate the device. Typical distances between the electrodes is 1 to 3 microns. MSM photodetectors may also have an anti-reflective (AR) coating on the top surface to minimize light loss due to reflection at the surface. The AR coating layer is adjusted to a quarter wave length thickness and the effective index is the geometrical average between the air (or other encapsulant) and the semiconductor. The typical number for the effective index is 1.9.
[0026] FIG. 2 depicts an example of an exploded view of a MSM photodetector and a connector 201 according to embodiments of the invention. This arrangement 200 includes a plurality of fibers 101 , the light from which is received by an array of photodetectors 106 . The fibers are arranged and maintained in the arrangement by holder 203 . A plurality of lenses 107 focus the light onto the array of photodetectors 106 . The lenses 107 may be separate from the array or they may be integrated with the array. The array is attached to a substrate 202 , which can be a PCB, a silicon substrate, a ceramic substrate, a dielectric substrate, or a metal frame substrate. The fiber holder 203 would then be coupled to the connector 201 , and the connection would align, within an acceptable tolerance, the fibers with the photodetectors. Note that more or fewer fibers can be used, e.g. 1, 4, 8, 12, or 36.
[0027] FIG. 3 depicts an arrangement 300 similar to that of FIG. 2 , but uses element 302 that reflects the light at an angle with respect to the direction of its entrance into the connector 301 . Note that element 302 may also focus the light as with lens 107 , in addition to changing its direction. Further note that the 90 degree change is by way of example only as other angles could be used.
[0028] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. | One embodiment of the invention uses an MSM photodetector that is coupled to a relatively large core optical waveguide, e.g. an HCS fiber or a plastic optical fiber (POF). The MSM photodetector with its low capacitance enables high speed data transmission using large core optical waveguides. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an information recording medium and a process for production thereof. The invention relates particularly, although not exclusively to a reliable information recording medium which is resistant to forgery and a process for production thereof.
2. Related Background Art
To date magnetic recording cards, such as credit cards or bank cards and so on have been used as portable information recording media. In recent years, IC cards, optical cards and so on have been proposed as a portable information media which have a larger recording capacity. Using such a larger recording capacity, it has been proposed to use such media as electric money or bank cards capable of recording dealings with a bank.
In such portable information media which are used to record important information relating to money and so on, it is important that improper use of the media, such as the use of stolen or lost information recording media, is difficult, and faking of the media is also difficult.
One method of preventing faking of a medium, is to provide a picture of the medium owner's face personal data, or data relating to the distributor of the information recording media etc., as holographic information in the information recording medium as initial information before distribution of the medium.
In order to produce such a medium, various methods are used in order to create difficulties in faking the information on the recording medium. For example it is known to form the above mentioned initial information on a thin sheet and attach the sheet to a card. In addition to providing such initial information, a lot of media processing is used for the purpose of preventing fake media. For example in a laminate type card in which a transparent sheet is laminated on an information sheet, it is possible to insert a watermark or special microprint.
In particular where such an information recording medium has a large recording capacity intended for extensive use, if the information recording medium is faked, the social effect is forecast to be very large.
Therefore in such an information recording medium, it is necessary to provide information which is more difficult to fake in order to prevent faking of the information.
SUMMARY OF THE INVENTION
An object of this invention is to provide an information recording medium which is difficult to fake. Another object of this invention is to provide a process for production of an information recording medium which is difficult to fake.
According to a first aspect of the invention there is provided an information recording medium comprising a stack of layers including a recording layer interposed between two shielding layers, the shielding layers being opaque to radiation within a predetermined waveband, (i.e., having a wavelength band that is used to record information to the recording layer or read information stored in the recording layer) said recording layer being adjacent to at least one layer which is transparent to radiation within the predetermined waveband, the recording layer being readable from an edge of the medium by radiation within the predetermined waveband passing into said one layer.
According to a second aspect of the invention there is provided a process for production of an information recording medium according to the first aspect of the invention including the steps of forming said stack of layers and laminating said stack of layers.
In a medium in accordance with the first aspect of the invention, information in the first recording layer may be reproduced only from the edge of the information recording medium, the first recording layer being embedded in the recording medium.
When such an information recording medium is faked, it is necessary to reproduce the medium production from the beginning. Therefore, there are more steps required to produce a fake, as compared to a recording medium that uses fake preventing means comprising only attaching an initial information recorded sheet with media according to the invention, it is possible to obtain more valuable fake preventing effect than prior art media.
As it is difficult to alter, it is possible to prevent the improper use of stolen or picked up information recording media.
The design of the medium to reduce the possibility of faked media being produced does not reduce the display region which may be used for display of information on the surface of the information recording medium. In recent years, it has been proposed that a portable information recording medium comprises an IC chip, an optical recording part, or a hybrid type medium including a plurality of information recording means such as a magnetic recording area. It is preferable that an electrode of an IC chip or magnetic recording area is exposed from the information recording medium. In this invention, the information for the sake of fake preventing does not affect the freedom of placing the information recording means such as the IC chip or magnetic recording part.
BRIEF DESCRIPTION OF THE DRAWINGS
A number of embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:
FIG. 1 ( a ) is a schematic isometric view of an information recording medium in accordance with a first embodiment of the invention.
FIG. 1 ( b ) is a schematic plan view of the information recording medium shown in FIG. 1 ( a ).
FIG. 2 is a schematic cross sectional view taken on line 2 — 2 of FIG. 1 ( b ).
FIG. 3 is a schematic cross sectional view of an information recording medium in accordance with a second embodiment of the invention.
FIG. 4 is a schematic cross sectional view of an information recording medium in accordance with a third embodiment of the invention.
FIGS. 5 ( a ), 5 ( b ) and 5 ( c ) are respectively schematic cross sectional views of an information recording medium in accordance with three variations of a fourth embodiment of the invention.
FIGS. 6 ( a ) and 6 ( b ) are respectively schematic cross sectional views of an information recording medium in accordance with two variations of a fifth embodiment of the invention.
FIGS. 7 ( a ), 7 ( b ) and 7 ( c ) are respectively schematic cross sectional views of an information recording medium in accordance with three variations of a sixth embodiment of the invention.
FIG. 8 is a schematic cross sectional view of an information recording medium provided with a reflection layer in accordance with a seventh embodiment of the invention.
FIG. 9 is a schematic cross sectional view of an information recording medium provided with a reflection layer in accordance with an eighth embodiment of the invention.
FIGS. 10 ( a ) and 10 ( b ) are respectively schematic cross sectional views of an information recording medium provided with an opaque protective layer in accordance with two variations of a ninth embodiment of the invention.
FIG. 11 is a schematic cross sectional view of an information recording medium provided with an opaque substrate in accordance with a tenth embodiment of the invention.
FIG. 12 ( a ) is a schematic plan view of an information recording medium in accordance with an eleventh embodiment of the invention.
FIG. 12 ( b ) is a schematic cross sectional view taken on line 12 ( b )— 12 ( b ) of the FIG. 12 ( a ).
FIG. 13 is an explanatory view of the card of FIG. 12 referred to in EXAMPLE 5.
FIG. 14 is an explanatory view of the card of FIG. 7 ( c ) as referred to in EXAMPLE 6.
DETAILED DESCRIPTION OF THE INVENTION
FIRST EMBODIMENT
FIGS. 1 and 2 illustrate schematically an information recording medium in accordance with a first embodiment of the invention. The medium comprises an optical card 1 including a substrate 3 carrying an optical recording layer (first recording layer) 5 capable of recording and reproducing optical information. A protective layer 7 is attached by means of an adhesive layer 9 on the surface of the substrate 3 to the surface carrying the first recording layer 5 . A hard coat layer 11 is formed on the opposite surface of the substrate to the first recording layer 5 . The hard coat layer 11 is effective to prevent the surface of the substrate 3 from being damaged by an incident light beam 13 for example, in the infrared region wave length band which is used for recording and reproducing information.
The substrate 3 is transparent to the incident infrared light beam 13 and to visible light. The protective layer 7 and the adhesive layer 9 are transparent at least to visible light. Two stripes forming a second recording layer 15 which carries particular information are formed on the surface of the protective layer 7 remote from the substrate 3 using a printed ink which appears blue under visible light.
A first shielding layer 17 is formed on the surface of hard coat 11 remote from the substrate 3 . The second recording layer 15 is arranged such that the second recording layer 15 is not visible under visible light from the substrate side of the optical card 1 due to first shielding layer 17 . The second recording layer 15 is also not visible from the protective layer 7 side of the optical card 1 because of a second shielding layer 19 formed on the protective layer 7 .
Thus the second recording layer 15 is not visible from either the substrate 3 side or the protective layer 7 side of the optical card 1 because of the shielding layers 17 and 19 . However, as shown in FIG. 1 ( a ) the second recording layer 15 is visible under visible light from the edge of the card 1 through the substrate 3 , the protective layer 7 and the adhesive layer 9 which are transparent as to the visible light. As the second recording layer 15 is not visible from the major surfaces of the card 1 because of the shielding layers 17 and 19 , it is possible to tell a genuine optical card from a simple fake optical card which copies the position of the recording layer 5 of a genuine optical card, by the existence of the second recording layer 15 .
If such an optical card is going to be faked, it is necessary to form the second recording layer 15 so as to contact the transparent protective layer 7 . If a print layer is going to be formed for example by remodelling an existing optical card, it is necessary to remove the shielding layer 19 on the protective layer 7 , to prepare the transparent surface of the protective layer 7 , to form the second recording layer 15 on the surface of the protective layer 7 , and to form the shielding layer 19 . In this case many steps are needed to provide a fake card including the second recording layer 15 . As can be seen, the inclusion of the second recording layer 15 increases the difficulty of faking the optical card, and thus increases the reliability of the optical card.
As the second recording layer 15 is not recognizable from the major surfaces of the card 1 , it is, as an option, possible to design the surface of the shielding layer 17 to make it more difficult to fake the optical card, for example by providing information using for example printing on the surface of the shielding layer 17 . If such an optical card is going to be faked, it is necessary to form printed information on the surface of the shielding layer 17 in addition to forming the second recording layer 15 contacting the transparent protective layer 7 . In this case the difficulty in producing take cards increases further.
The information carried in the second recording layer 15 is not restricted as long as it is recognizable from the side of the optical card 1 . In particular, visible patterns, characters, designs and so on can be used. As for the color of the information, all colors are available if they are not visible through the major surfaces of the card 1 . In particular a fluorescent ink is preferable because it is more easily recognized.
In an optical card according to this embodiment, the method of forming the second recording layer 15 is not restricted as long as it is possible to provide the desired information on the surface of the protective layer 7 . Thus, for example known methods such as gravure coating are available.
The kind or color of the information can be changed to suit the distributor of the optical card, for example a credit card company or bank. Even if the distributor is the same for all cards, it is possible to change the color or information according to the year of distribution. In this case the difficulty of producing fake cards increases further.
With regard to the distance between the second recording layer 15 and the first shielding layer 17 , this is preferably more than 150 pm, more preferably more than 400 μm, so as to increase the certainty of recognition of the information from the side of the optical card 1 . If the transparent layer 7 between the second recording layer 15 and the first shielding layer 17 comprises laminated layers of different materials, the total thickness of the laminated layers may be chosen to meet the above mentioned condition. In particular where the protective layer 7 is fixed to the substrate 3 with an adhesive layer 9 , and the adhesive layer 9 is transparent, making the total thickness of the protective layer 7 and the adhesive layer 9 satisfy the above mentioned condition, this increases the ease of reading the information which is carried in the second recording layer 15 from the side of the card 1 . In this case, if the difference of the refractive index of layers which are comprised of different materials is within 0.2, especially within 0.1 there is little reflection at the interfaces between the transparent layers. Therefore it is easy to recognize accurately the information in the second recording layer 15 from the side of the card 1 .
As the shielding layers 17 and 19 , an opaque layer which prevents the second recording layer 15 from being recognized from the major surfaces of the optical card 1 under visible light may be used. By “opaque” is meant a transmissivity of the information of the second recording layer 15 with a particular reproducing light of 5% or less, preferably 2% or less. Examples of such layers include a printed layer, plastic film, metal sheet and opaque paper which includes a certain quantity of pigments (titanium oxide, aluminium oxide etc.), or metal particles (aluminium etc.). The shielding layers 17 , 19 composed of a printed layer may be formed by, for example, providing ink including the above mentioned pigments or metal particles on a surface using a known printing method. If a plastic film, metal sheet or paper is used, it is attached to the surface of the optical card 1 using for example adhesive glue.
In the embodiments of this invention, the shielding layers can be layers which provide other functions for the optical card. For example, as the shielding layer 17 , a resin film carrying a magnetic stripe constituting a magnetic recording layer for the optical card 1 can be used. The shielding layer 19 can be a printed layer which provides information on the surface of the protective layer 7 or an underlying layer.
The substrate 3 of the optical card 1 , may be formed from, for example, glass plate, plastic resins such as polycarbonate, polyvinylchloride, or polymethylmethacrylate.
If at least one of a recording light beam and a reproducing light beam is used to irradiate the first recording layer 5 through the substrate 3 , an a durable hard coat layer 11 which protects the surface of the substrate 3 from flaws or dust is useful. A thin film of light setting type resin, epoxy resin, acrylate resin, silicone resin are examples of suitable materials for the hard coat layer 11 .
Everything such as magnetic stripes, design printing, bar code, OCR characters, hologram, sign panels and so on, which are provided on conventional credit cards can be provided on the surface of the optical card substrate 3 .
As the first recording layer 5 , any optical recording materials which are capable of being recorded or reproduced by a laser beam may be used, for example organic dye recording materials, and metallic recording materials. A reflective layer, an underlying layer and so on can be added.
As the adhesive layer 9 , the usual adhesive agent may be used. Examples of suitable materials are polymer or copolymer of vinyl monomer such as vinyl acetate, acrylic acid ester, vinyl chloride, ethylene, acrylic acid, acrylic amide, thermoplastic adhesive glue such as polyamide, polyester, epoxy, adhesive glue such as amino resin (urea resin, melamine resin), phenol resin, epoxy resin, urethane resin, thermosetting vinyl resin, rubber adhesive glue such as natural rubber, nitrile rubber, chloro rubber, and silicone rubber.
As the protective layer 7 , the above mentioned materials which may be used for the optical card substrate 3 are usable because the protective layer 7 should also be transparent.
It is possible to provide an IC chip on at least one of the substrate 3 and the protective layer 7 to make a hybrid card which is capable of being recorded both by light and electrically.
SECOND AND THIRD EMBODIMENTS
FIG. 3 shows an adaptation of the first embodiment in which the first shielding layer 17 of the optical card 1 shown in FIG. 1 and FIG. 2 is located between the transparent substrate 3 and the transparent adhesive layer 9 .
FIG. 4 shows another embodiment in which the first shielding layer 17 shown in FIG. 1 and FIG. 2 is located between the transparent protective layer 7 and the transparent adhesive layer 9 .
FURTHER EMBODIMENTS
Other embodiments of an optical card in accordance with the invention will now be explained. Referring now also to FIGS. 5 and 6 the cards shown in these figures differ from the optical card shown in FIGS. 1 and 2 in that the second recording layer 15 is provided between the substrate 3 and the protective layer 7 .
In the embodiments shown in FIG. 5 the second recording layer 15 is provided between the protective layer 7 and the adhesive layer 9 .
In the embodiments shown in FIG. 6, the second recording layer is provided between the adhesive layer 9 and the substrate 3 . In this case, it is preferable to provide the first shielding layer 17 on either or both of the side of the substrate 3 remote from the protective layer 7 , and between the second recording layer 15 and the substrate 3 . It is preferable to provide the second shielding layer 19 on either or both of the side of the protective layer 7 remote from the substrate 3 , and between the protective substrate 7 and the second recording layer 15 . If the first shielding layer 17 is provided between the substrate 3 and the second recording layer, it is preferable to provide the second shielding layer 19 on the side of the protective layer 7 which is remote from the substrate 3 . If the second shielding layer is provided between the protective layer 7 and the second recording layer 15 , it is preferable to provide the first shielding layer 17 on the side of the substrate 3 which is remote from the protective layer 7 . In these arrangements it is possible to make a transparent layer contact with the second recording layer 15 . Recognition of the information carried in the second recording layer 15 from the side of the optical card 1 thus becomes easy.
In FIG. 5 ( a ) the first shielding layer 17 is provided at the side of the substrate 3 remote from the protective layer 7 and the second shielding layer 19 is provided on the surface of the protective layer 7 which is remote from the substrate 3 .
In FIG. 5 ( b ) the first shielding layer 17 is provided on the surface of the second recording layer 15 which opposes the substrate 3 . In FIG. 5 ( c ) the second shielding layer 19 is provided between the protective layer 7 and the second recording layer 15 .
In FIG. 6 ( a ) the first shielding layer 17 is provided on the side of the substrate 3 which is remote from the protective layer 7 , and the second shielding layer 19 is provided on the surface of the protective layer 7 which is remote from the substrate 3 .
In FIG. 6 ( b ) the first shielding layer 17 is provided between the substrate 3 and the second recording layer 15 and the second shielding layer 19 is provided on the surface of the protective layer 7 which is remote from the substrate 3 .
Turning now to the embodiments illustrated in FIG. 7, the optical cards shown in FIGS. 7 ( a ), 7 ( b ) and 7 ( c ) are different from the optical cards shown in FIGS. 1 and 2 in that the second recording layer 15 is provided on one side of the substrate 3 which is remote from the protective layer 7 .
In this case, it is preferable to provide the first shielding layer 17 on the surface of the second recording layer 15 which is remote from the substrate 3 , and to provide the second shielding layer 19 on either or both of the surface of the protective layer 7 which is remote from the substrate 3 , and between the protective layer 7 and the second recording layer 15 . In particular, in FIG. 7 ( a ) the first shielding layer 17 is provided on the surface of the second recording layer 15 remote from the substrate 3 , whilst the second shielding layer 19 is provided on the surface of the protective layer 7 remote from the substrate 3 .
In FIG. 7 ( b ) the first shielding layer 17 is provided on the surface of the second recording layer 15 which is remote from the protective layer 7 , whilst the second shielding layer 19 is provided between the protective layer 7 and the adhesive layer 9 .
The embodiment shown in FIG. 7 ( c ) is different from that of FIG. 7 ( b ) in that the second shielding layer 19 is provided between the adhesive layer 9 and the substrate 3 .
FIGS. 8 and 9 show optical cards in which a reflective layer 21 is added to the optical card shown in FIG. 2 . In the embodiment shown in FIG. 8, the reflective layer 21 is provided on the surface of the protective layer 7 which opposes the substrate 3 . The reflective layer 21 is not recognizable from the substrate 3 side of the card 1 because of the existence of the first shielding layer 17 . If the reflective layer 21 is provided on the second recording layer 15 with a transparent layer therebetween, there is an advantage that it is easier to recognize the second recording layer 15 from the edge of the card 1 . It is possible to read information recorded on the second recording layer 15 from the edge of the card 1 , although information is located inside the card 1 . Therefore it is useful when the second recording layer 15 carries much information.
The reflective layer 21 may be formed for example from metal foil or metal evaporated resin film. The reflective layer 21 is attached to the card with adhesive agent. The position of the reflective layer 21 is not restricted to the surface of the protective layer 7 which is remote from the second recording layer 15 . For example if the adhesive layer 9 is transparent, the reflective layer can be provided at the interface between the adhesive layer 9 and the substrate 3 , or at the interface between the substrate 3 and the transparent protective layer 11 , or at the interface between the transparent protective layer 11 and the shielding layer 17 .
The reflective layer 21 can alternatively be provided between the second recording layer 15 and the second shielding layer 19 so as to contact the second recording layer 15 . In this case contrast of the information which is carried in the second recording layer increases, and reproduction of the information becomes easier.
Instead of inserting the reflective layer 21 in the card 1 , the reflective layer 21 may be formed by evaporating or sputtering metal on at least one of the side of the first shielding layer 17 which opposes the second recording layer 15 and the side of the second shielding layer 19 which opposes the second recording layer 15 .
The reflective layer 21 can be included in all the optical cards shown in FIGS. 3 to 7 . For example in FIG. 3, the reflective layer 21 can be formed at a position between the shielding layer 17 and the transparent protective layer 11 , or between the transparent protective layer 11 and the substrate 3 , or between the substrate 3 and the adhesive layer 9 .
The reflective layer 21 can be formed in a number of positions. In particular the reflective layer 21 can be formed between the second recording layer 15 and the protective layer 4 , between the shielding layer 17 and the transparent protective layer 11 , between the transparent protective layer 11 and the substrate 3 , between the substrate 3 and the adhesive layer 9 , or between the second recording layer 15 and the protective layer 7 . It a reflective layer 21 is provided at both the positions of between the first shielding layer 17 and the second recording layer 15 , and between the second shielding layer 19 and the second recording layer, it is preferable that at least one surface of the second recording layer 15 contacts a transparent member for example the protective layer 7 or the adhesive layer 9 .
In the embodiment shown in FIG. 6 ( a ) the reflective layer 21 can be provided between the first shielding layer 17 and the second recording layer 15 , for example between the shielding layer- 17 and the protective layer 11 , between the protective layer 11 and the transparent substrate 3 , or between the transparent substrate 3 and the second recording layer 15 . The reflective layer 21 may be provided between the second recording layer 15 and the second shielding layer 19 , for example between the second recording layer 15 and the adhesive layer 9 , between the adhesive layer 9 and the transparent protective layer 7 , or between the transparent layer 7 and the second shielding layer 19 . The reflective layer 21 may be provided between the first shielding layer 17 and the second recording layer 15 , and between the second shielding layer 19 and the second recording layer 15 . In this case it is preferable that at least one surface of the second recording layer IS contact a transparent member for example the transparent substrate 1 or the transparent adhesive layer 9 .
In the card shown in FIG. 7 ( a ) the reflective layer 21 may be provided between the first shielding layer 17 and the second recording layer 15 . The reflective layer 21 may be provided between the transparent substrate 3 and the transparent adhesive layer 9 , between the transparent adhesive layer 9 and the transparent protective layer 7 , or between the transparent protective layer 7 and the second shielding layer 19 . The reflective layer 21 may be provided at a position between the first shielding layer 17 and the second recording layer 15 , between the transparent substrate 3 and the transparent adhesive layer 9 , between the transparent adhesive layer 9 and the transparent protective layer 7 , or between the transparent protective layer 7 and the second shielding layer 19 .
In the cards shown in FIGS. 8 and 9, if the reflective layer 21 is provided both between the first shielding layer 17 and the second recording layer 15 , and between the second recording layer 15 and the second shielding layer 19 , it is preferable that at least one surface of the second recording layer 15 contacts a transparent member, for example the transparent substrate 1 , the transparent adhesive layer 9 or the transparent protective layer 7 . In these cases it is easier to reproduce information carried in the second recording layer from an edge of the optical card 1 .
In the cards shown in FIGS. 5 to 7 , the protective layer 7 may be opaque to the light which is used for reproducing information carried in the second recording layer 15 , for example visible light. For example in FIG. 10, an opaque to visible light protective layer 23 is substituted for the protective layer 7 of the optical card shown in FIG. 5 ( a ). In this case the shielding layer 19 shown in FIG. 5 ( a ) can be omitted.
In the cards shown in FIGS. 2 to 6 , the substrate 3 may be opaque for the light which is used for reproducing information carried in the second recording layer 15 , for example visible light. For example in FIG. 11, an opaque substrate 25 is substituted for the substrate 3 of the optical card shown in FIG. 2 . In this case the first shielding layer 17 can be omitted. If the opaque substrate 25 is also opaque to the light used for recording information in the first recording layer, or used for reproducing information carried in the first recording layer, it is preferable to provide the second shielding layer 19 at a suitable position which creates no difficulty in recording in the first recording layer and reproducing information carried in the first recording layer by the light passing through the protective layer 7 .
It is possible to apply the above mentioned reflective layer to cards which comprise an opaque substrate or opaque protective layer. In the optical card shown in FIG. 10, it is possible to provide a reflective layer between the first shielding layer 17 and the surface protective layer 11 , between the surface protective layer 11 and the transparent substrate 3 , or between the transparent substrate 3 and the transparent adhesive layer 9 .
In the optical card shown in FIG. 11, it is possible to provide a reflective layer 21 between the opaque substrate 25 and the transparent adhesive layer 9 , between the transparent adhesive layer 9 and transparent protective layer 7 , or between the second recording layer and the second shielding layer 19 .
Referring now to FIGS. 12 ( a ) and 12 ( b ), in the embodiment shown in these Figures the first recording layer 5 is formed on the region 101 of the side of the substrate 3 where a preformat (not shown) is formed. The first recording layer 5 is made of a metallic material and thus acts as a reflective layer. As the first recording layer 5 is opaque, if the first recording layer 5 is provided on the substrate 3 and the second recording layer 15 is provided on a region of the protective layer 7 which is overlaid by the first recording layer 5 , it is possible to make the first recording layer function as the reflective layer 21 and the second shielding layer 19 . Information carried in the second recording layer 15 can be reproduced only from the edge of the optical card 1 through the transparent protective layer 7 , or the transparent protective layer 7 and transparent adhesive layer 9 . Recognition of the information from the edge of the optical card is easier because of existence of the reflective layer 21 .
In the above described embodiments of the invention, the following advantages may be obtained.
(1) As various information about the card such as a collation mark, manufacturing date, ID information and so on can be carried in the second recording layer which is located inside the card, it is difficult to fake the card. Thus a reliable information recording medium can be obtained.
(2) As the second recording layer 15 which carries the various information is provided next to a transparent layer, and the information carried in the second recording layer 15 can be reproduced only from the edge of the information recording medium, the design of the visible information (for example pictures, photographs, characters, numbers and so on) which is usually provided on the front surface or the back surface of the information medium is not restricted.
(3) As the second recording layer 15 is sealed inside the information recording medium, it is rare that an edge of the medium is rubbed and reading is difficult as a result of flaws. If the edge part is overwritten with fake information, it will be apparent that forgery has taken place. If the second recording layer 15 is to be faked, the laminated structure of the card will have to be destroyed, thus making undetectable faking difficult.
(4) If a reflective layer 21 is provided, it becomes easier to recognize information in the second recording layer 15 , and the depth of scope which is readable becomes deeper. Therefore plane information such as character information can be read from the edge of the medium, and it is possible to increase the amount of readable information.
In the following examples of recording media in accordance with embodiments of the invention, and the comparative example not in accordance with the invention, the transmissivity of an opaque shielding layer was measured with a spectrophotometer (trade name:MCPD-1000 (Otsuka Electronics Co. Ltd.)).
EXAMPLE 1
This example describes the production of the optical card 1 shown in FIG. 5 ( b ).
The production of the transparent protective layer 7 provided with the second recording layer 15 and the second shielding layer 19 will now be described.
On one side of a polycarbonate transparent substrate of area 100 mm×100 mm, and thickness 0.3 mm forming the transparent protective layer 7 , an opaque printed layer having a transmissivity of 2% or less for visible light was formed by gravure coating using a black ink comprising 2 weight parts of carbon black pigment added to 10 weight parts of a vinyl chloride ink, this opaque printed layer constituting the second shielding layer 19 .
Referring now also to FIG. 13, on the other side of the polycarbonate transparent substrate 7 , the second recording layer 15 in the form of two stripes of 3 mm width and 10 mm length was formed using a two liquid setting type urethane acrylate blue ink (3 weight parts of a blue pigment (No. 440) having a 5 μm average particle size and 1 weight part of HAC curing agent were mixed with 10 weight parts of RAC ink medium; Seiko Advance Inc.). An opaque first shielding layer 17 of thickness 20 μm and a transmissivity of 2% or less for visible light was formed so as to cover the second recording layer 15 by gravure coating with a white ink comprising 10 weight parts of vinyl chloride ink and 3 weight parts of titanium oxide pigment.
The production of the transparent substrate 3 provided with a first recording layer 5 and a surface protective layer 11 will now be described.
A polycarbonate transparent substrate 3 of area 100 mm×100 mm, and thickness 0.4 mm was formed to have on one side a preformat (not shown) for the optical card. On the other side of the substrate 3 a urethane acrylate UV setting resin (trade name: UNIDIC (Dainippon Ink and Chemicals Inc.)) was spin coated to 4 μm thickness and hardened using a UV lamp (80 W/cm) to form a transparent hard coat layer constituting the transparent protective layer 11 . On the region of the substrate 3 designed to carry the first recording layer 5 , that is the region of the substrate 3 , formed into a preformat, a 3 wt % diacetone alcohol solution of 1,1,5,5,-tetrakis (p-diethylaminophenyl) 1,2,4-pentadieniumperchlorate was coated by gravure coating and dried, to form a layer of thickness 1000 Å constituting the first recording layer 5 .
In order to produce the optical card 1 , the transparent protective layer 7 and the substrate 3 were attached using an ethylene vinylacetate hot-melt type adhesive (trade name: HIRODINE 7500 (Hirodine Kogyo Co. Ltd.)) so that the first shielding layer 17 and the first recording layer 5 were on opposing surfaces as shown in FIG. 5 b . The attached substrates were die cut into 85.6 mm×54 mm rectangles to form an optical card of the required size.
Observing the optical card through the edge adjacent to the second recording layer 15 , the two blue stripes of the second recording layer 15 were recognizable through the transparent protective layer 7 . On the other hand observing the optical card from either of the major surfaces of the card, it was impossible to recognize the second recording layer 15 .
EXAMPLE 2
The production of the optical card shown in FIG. 10 ( b ) will now be described.
Firstly, the production of the transparent substrate 3 provided with the first recording layer 5 , the second recording layer 15 , the surface protective layer 11 and the first shielding layer 17 will be described.
A polycarbonate transparent substrate 3 of area 100 mm×100 mm, and thickness 0.4 mm was formed on one side with a preformat (not shown) for the optical card. On the other side of the substrate 3 a urethane acrylate UV setting resin (trade name: UNIDIC (Dainippon Ink and Chemicals Inc.)) was spin coated to 4 μm thickness and hardened using a UV lamp (80 W/cm) to form a transparent hard coat layer constituting the transparent protective layer 11 . On the region of-the substrate 3 designed to carry the first optical recording layer 5 , that is the region including optical recording the preformat formed surface of the substrate 3 , a 3 wt % diacetone alcohol solutionof 1,1,5,5,-tetrakis(p-diethxlaminophenyl) 1,2,4-pentadieniumperchlorate was coated by gravure coating and dried to form a layer of thickness 1000 Å constituting the first recording layer 5 .
The second recording layer 15 comprising two stripes was of 3 mm in width, and of 10 mm in length was formed at a chosen position of the same surface of the substrate 3 as the first recording layer 5 , using a two liquid setting type urethane acrylate red ink having 3 weight parts of a red pigment (No. 500) and a 5 μm average particle size, and 1 weight part of HAC curing agent composed of an isocyanate resin mixed with 10 weight parts of HAC ink medium(Seiko Advance Inc.). A printed layer whose thickness was 10 μm was formed on a region of the transparent protective layer 11 carried by the substrate 3 in a corresponding position to the second recording layer 15 region by printing a two liquid setting type urethane acrylate black ink (3 weight parts of a black pigment (No. 710) having a 5 μm average particle size and 1 weight part of HAC curing agent mixed with 10 weight parts of HAC ink medium; Seiko Advance Inc.) using a mesh 200 screen block. The printed layer had a transmissivity of 2% or less and functioned as the first shielding layer 17 for shielding the second recording layer 15 .
In order to prepare a protective layer 23 opaque to visible light a 20 μm white ink (trade name: SERICOL 13-611 WHITE (Teikoku Printing Inks Mfg. Co. Ltd.)) which was used in EXAMPLE 1 was printed on one side of a white vinylchloride sheet (size 100 mm×100 mm, thickness 0.3 mm).
To produce the optical card 1 , the prepared substrate 3 and the protective layer 23 were attached using a 60 μm hot-melt type adhesive (trade name: EVAFLEX 7580 (Hirodine Kogyo Co. Ltd.)) composed of ethylene-vinylacetate co-polymer so that the first recording layer 5 was opposed to the printed layer unformed surface of the protective layer 23 . The attached layers were die cut into a 85.6 mm×54 mm rectangle to form an optical card of the required size.
Observing the optical card 1 through the edge adjacent the second recording layer 15 , two red stripes were recognizable through the 0.3 mm thickness transparent substrate 3 . On the other hand observing the optical card 1 directly through the two major surfaces, it was impossible to recognize the-second recording layer 15 .
EXAMPLE 3
This example describes the production of the optical card shown in FIG. 6 ( b ).
The production of the transparent substrate 3 provided with the first recording layer 5 , the first shielding layer 17 , a second recording layer 15 and the surface protective layer 11 will first be described.
A polycarbonate transparent substrate 3 of area 100 mm×100 mm, and thickness 0.4 mm was provided on one side with a preformat for the optical card. On the other side of the substrate 3 a urethane acrylate UV setting resin (trade name: UNIDIC (Dainippon Ink and Chemicals Inc.)) was spin coated to 4 μm thickness and hardened using a UV lamp (80 W/cm) to form a transparent hard coat layer constituting the transparent protective layer 11 . On the optical recording region indicated as 5 in FIG. 13 of the preformat formed surface of the substrate, a 3 wt % diacetone alcohol solution of 1,1,5,5,-tetrakis (p-diethylaminophenyl) 1,2,4-pentadieniumperchlorate was coated by gravure coating and dried to form a layer 5 of thickness 1000 Å constituting the first recording layer 5 .
On the surface of the substrate 3 carrying the first recording layer 5 at a position separate from the first recording layer 5 , a white ink (trade name: SERICOL 13-611 WHITE (Teikoku Printing Inks Mfg. Co. Ltd.)) as was used in EXAMPLE 1 was gravure coated to prepare a 20 μm white opaque printed layer constituting the first shielding layer 17 . Then a second recording layer 15 was formed on the first shielding layer 17 in the same way as EXAMPLE 1.
In order to produce a protective layer 7 provided with a second shielding layer 19 , a white ink (trade name: SERICOL 13-611 WHITE (Teikoku Printing Inks Mfg. Co. Ltd.)) as used in EXAMPLE 1 was gravure coated on one side of a transparent polycarbonate substrate of area 100 mm×100 mm, and thickness 0.3 mm.
This produced a 20 μm printed layer acting as a second shielding layer 19 having a transmissivity of 2% or less for visible light.
In order to produce the optical card, the prepared substrate 3 and the protective layer 7 were attached in the same way as in EXAMPLE 1 so that the first recording layer 5 carried by the substrate 3 opposed the second shielding layer 19 formed on the surface of the protective layer 7 . Then the attached layers were die cut to the required size to form an optical card.
Observing the side of the optical card where the second recording layer was exposed, two blue stripes were recognizable through the transparent adhesive layer 9 and the transparent protective layer 7 . On the other hand observing the optical card directly through the two major surfaces, it was impossible to recognize the second recording layer 15 .
REFERENCE EXAMPLE
A transparent substrate 3 provided with a first recording layer 5 , a first shielding layer 17 , a second recording layer 15 and a surface protective layer 11 was produced in the same way as EXAMPLE 3. Then the same protective layer 7 as the optical card in EXAMPLE 3 was prepared.
The prepared substrate 3 and the protective layer 7 were attached the same way as in EXAMPLE 1 so that the first recording layer 5 of the substrate 3 opposed the printed layer 19 formed on the surface of the protective layer 7 . The attached substrates were die cut to form an optical card.
Observing the optical card through the edge adjacent to the second recording layer, it was difficult to recognize two blue stripes because the thickness of the transparent layer which one surface of the second recording layer contacted was only 60 μm, that is the thickness of the transparent adhesive.
EXAMPLE 4
This example describes the production of the optical card shown in FIG. 8 .
Firstly the production of the protective layer 7 provided with the second recording layer 15 , the second shielding layer 19 and the reflective layer 21 will be described.
A polycarbonate transparent substrate 7 of area size 100 mm×100 mm, and thickness 0.4 mm and a second recording layer 15 were formed in the same way as in EXAMPLE 1. A white ink (trade name: SERICOL 13-611 WHITE (Teikoku Printing Inks Mfg. Co. Ltd.)) as used in EXAMPLE 1 was gravure coated so as to cover the whole of the second recording layer 15 to produce a 20 μm printed layer to act as the second shielding layer 19 . At a position corresponding to the position of the second recording layer 15 but on the opposite side of the transparent substrate 7 an aluminum foil of thickness 15 μm was hot-stamped to form a reflective layer 23 .
The production of the transparent substrate 3 , the first recording layer 5 , the surface protective layer 11 , and the first shielding layer 17 will now be described.
A polycarbonate transparent substrate 3 of area 100 mm×100 mm, and thickness 0.4 mm having on one side a preformat (not shown) for an optical card was formed. On the other side of the substrate 3 a urethane acrylate UV setting resin (trade name: UNIDIC (Dainippon Ink and Chemicals Inc.)) was spin coated to 4 μm thickness and hardened using a UV lamp (80 W/cm) to form a transparent hard coat layer constituting the transparent protective layer 11 . In the region designed to be the optical recording region on the surface of the substrate including the preformat, a 3 wt % diacetone alcohol solution of 1,1,5,5,-tetrakis diethylaminophenyl) 1,2,4-pentadieniumperchlorate was coated by gravure coating and dried to form a layer of thickness 1000 Å constituting the first recording layer 5 .
A first shielding layer 17 whose transmissivity was 2% or less designed to shield the second recording layer 15 was formed on the transparent protective layer 11 of the substrate using a two liquid setting type urethane acrylate white ink (3 weight parts of a white pigment (No. 120) having 5 μm average particle size and 1 weight part of HAC curing agent mixed with 10 weight parts of HAC ink medium; Seiko Advance Inc.). The first shielding layer 17 was dried to form a 20 μm thickness.
In order to produce the optical card, the prepared substrate 3 and the protective layer 7 were attached as in EXAMPLE 1 so that the reflective layer 21 carried by the protective layer 7 opposed the first recording layer 5 carried by the substrate 3 . Then the attached substrates 3 , 7 were die cut to the correct size to form an optical card.
Observing the optical card through the edge adjacent the second recording layer 15 , two blue stripes were recognizable through the transparent protective layer 7 . On the other hand observing the optical card directly through either of two major surfaces of the optical card, it was impossible to recognize the second recording layer 15 .
EXAMPLE 5
This example describes the production of the optical card shown in FIG. 12 .
The production of a substrate 3 provided with a first recording layer 5 will first be described.
A polycarbonate transparent substrate of area 100 mm×100 mm, and thickness 0.4 mm was formed on one side with a preformat (not shown) for the optical card. On the other side of the substrate 3 , a urethane acrylate UV setting resin (trade name: UNIDIC (Dainippon Ink and Chemicals Inc.)) was spin coated to a 4 μm thickness and hardened using a UV lamp (80 W/cm) to form a transparent hard coat layer constituting the transparent protective layer 11 . In the region indicated as 101 in FIG. 12 ( a ) of the preformat formed surface of the substrate 3 , a tellurium film of 1200 Å was evaporated to form the first recording layer 5 .
The production of the transparent protective layer 7 provided with the second recording layer 15 , and the second shielding layer 19 will now be described.
In a position on one side of a polycarbonate transparent substrate of size 100 mm×100 mm, and thickness 0.4 mm overlaid by the first recording layer 5 of the substrate 3 as described, characters being a right-left reversed version of [OPTICAL CARD] were printed with the same blue ink used in EXAMPLE 1 for the second recording layer to form a second recording layer 15 . Then a white ink (trade name: SERICOL 13-611 WHITE (Teikoku Printing Inks Mfg. Co. Ltd.)) as used in EXAMPLE 1 was printed so as to cover the second recording layer 15 to prepare a 20 μm opaque layer having a transmissivity of 2% or less as to visible light, constituting the second shielding layer 19 .
In order to produce the optical card, the prepared substrate 3 and the protective layer 7 were attached the same way as in EXAMPLE 1 so that the first recording layer 5 carried by the substrate 3 was directed opposed towards the second recording layer 15 formed on the surface of the protective layer 7 . Then the attached substrates 3 , 7 were die cut to form an optical card.
Observing the optical card directly through the two major surfaces of the card, it was impossible to recognize the character information carried by the recording layer 15 formed inside the optical card. On the other hand observing the optical card through the edge adjacent the first recording layer 5 , the surface of the first recording layer 5 which was directed towards the second recording layer 15 functioned as a reflective layer 21 and the information carried in the second recording layer was reflected. Therefore it was possible to recognize the information through the transparent adhesive layer 9 and the transparent protective layer 7 .
EXAMPLE 6
This example describes the production of an optical card shown in FIG. 7 ( c ).
First, the production of a transparent protective layer 7 provided with a second recording layer 15 and a second shielding layer 19 will be described.
A polycarbonate transparent substrate 3 of area 100 mm×100 mm, and thickness 0.4 mm was formed on one side with a preformat (not shown) for an optical card. On the other side of the substrate 3 , a urethane acrylate UV setting resin (trade name: UNIDIC (Dainippon Ink and Chemicals Inc.)) was coated to 4 μm thickness by a bar coating method and hardened using a UV lamp (80 W/cm) to form a surface protective layer 11 .
On the region of the surface protective layer 11 where a magnetic stripe is going to be formed, a two liquid setting type urethane acrylate transparent ink (1 weight part of HAC curing agent mixed with 10 weight parts of HAC ink medium; Seiko Advance Inc.) and a two liquid setting type urethane acrylate red ink (3 weight parts of a red pigment (No. 510) having a 5 μm average particle size and 1 weight part of HAC curing agent mixed with 10 weight parts of HAC ink medium; Seiko Advance Inc.) were prepared as a receiving layer for the magnetic stripe.
Referring now also to FIG. 14, on a part of the second recording layer 15 in a position corresponded to an edge of the optical card the red-ink, and on the other part designed for formation of the magnetic stripe, the transparent ink were printed, using a mesh 200 screen block for both inks. Then the printed parts were dried to form the magnetic stripe receiving layer composed of the 10 μm thick red second recording layer and the transparent printed layer.
An opaque magnetic film (trade name: ISO-GEOO-114 (TOKYO JIKI INSATSU Co. Ltd.)) whose transmissivity was 2% or less and whose width was 11.4 mm, having an adhesive layer on its back surface, was then attached using the adhesive layer to the above mentioned receiving layer to form a first shielding layer 17 for shielding the second recording layer 15 .
On the optical recording region of the surface of the substrate 3 carrying the preformat, a 3 wt % diacetone alcohol solution of 1,1,5,5,-tetrakis (p-dietheylaminophenyl) 1,2,4-pentadieniumperchlorate was coated by gravure coating and dried to form a layer of thickness 1000 Å constituting the first recording layer 5 .
At a position on the surface of the substrate 3 carrying the preformat, corresponding to the position of the second recording layer 17 , a white ink (trade name: SERICOL 13-611 WHITE (Teikoku Printing Inks Mfg. Co. Ltd.)) as used in EXAMPLE 1 was printed to prepare a 20 μm white opaque printed layer having a transmissivity of 2% or less for visible light, this acting as the second shielding layer 19 .
A polycarbonate transparent substrate (size 100 mm×100 mm, thickness 0.3 mm) was prepared as the protective layer 7 .
The prepared substrate 3 and the protective layer 7 were attached the same way as in EXAMPLE 1 so that the first recording layer 5 carried by the substrate 3 is directed towards the protective layer 7 . The attached substrates 3 , 7 were die cut to form an optical card of the correct dimensions.
Observing the optical card through the edge adjacent the second recording layer 15 , it was possible to recognize the bar code through the transparent substrate 7 . On the other hand observing the optical card directly through either of the major surfaces of the optical card, it was impossible to recognize the second recording layer 15 .
EXAMPLE 7
In this example, an optical card was prepared in the same way as in EXAMPLE 6, except that a five figure number was used as the second recording layer inside the magnetic stripes in EXAMPLE 6 each number being 1 mm×1 mm in size, and the shielding layer 17 was provided on the side of the protective layer 7 which contacted with the adhesive layer 9 .
It was impossible to recognize the information in the second recording layer 15 from either of the major surfaces of the card. However, the five figure number was recognizable from the edge Of the card.
EXAMPLE 8
In this example, an optical card was prepared in the same way as in EXAMPLE 6, except that a picture of 2 mm×5 mm size instead of the bar code was used in the second recording layer inside the magnetic stripes in EXAMPLE 6, and the second shielding layer 19 was provided on the side of the protective layer 7 remote from the adhesive layer 9 .
The thickness of the substrate 3 was 0.4 mm. The thickness of the adhesive layer 9 was 60 μm. The thickness of the protective layer 7 was 0.3 mm.
Observing the card through the edge of the card adjacent the second recording layer, it was possible to recognize the picture pattern through the transparent substrate 3 , transparent adhesive layer 9 and the protective layer 7 . On the other hand observing the optical card directly from either of the major surfaces of the card, it was impossible to recognize the picture pattern.
EXAMPLE 9
This example describes the production of a magnetic tape carrying the second recording layer 15 on the surface.
A two liquid setting type urethane acrylate red ink (3 weight parts of a red pigment (No. 510) having 5 μm average particle size and 1 weight part of HAC curing agent mixed to 10 weight parts of HAC ink medium; Seiko Advance Inc.) was prepared and gravure coated on a region of an adhesive layer provided on a back surface of the magnetic film (trade name: ISO-GEOO-114 (TOKYO JIKI INSATSU CO. Ltd.)) used in EXAMPLE 6 corresponding to the edge of the card. The second recording layer composed of two stripes of 10 micron thickness, 3 mm width and 10 mm length was provided on the magnetic tape.
The production of the transparent protective layer 7 provided with the second shielding layer 19 and the second recording layer will now be described.
A transparent polycarbonate substrate (size 100 mm×100 mm, thickness 0.3 mm) was prepared as the protective layer 7 . The magnetic tape provided with the second recording layer was laminated on the protective layer 7 so that the side of the second recording layer 15 contacted the protective layer 7 . Then the substrates were pressed at 100° C. to unite the protective layer and the magnetic tape to form a transparent protective layer 7 provided with the second recording layer 15 . The magnetic stripes which had a transmissivity of 2% or less as to visible light acted as the second shielding layer 19 .
The transparent substrate provided with the first recording layer 5 , the surface protective layer 11 and the first shielding layer 17 were prepared the same way as in the EXAMPLE 4.
In order to produce the optical card, the prepared substrate 3 and the protective layer 7 were attached same way as in EXAMPLE 1 so that the side of the protective layer 7 on which the second recording layer 15 and the magnetic stripes were not provided was directed towards the side of the substrate 3 carrying the first recording layer 5 . Then the attached substrates were die cut to form an optical card.
Observing the card under visible light, it was possible to recognize the red stripes through the transparent substrate 3 , the transparent adhesive layer 9 and the transparent protective layer 7 . On the other hand observing the optical card directly through the major surfaces of the card, it was impossible to recognize the second recording layer 15 .
EXAMPLE 10
In this example, an optical card was prepared in the same way as in EXAMPLE 9, except that a five figure number of 1 mm×1 mm size was used as the information on the second recording layer 15 in EXAMPLE 9, and the first shielding layer 17 was provided on the side of the transparent substrate 3 which was opposed to the protective layer so that the first shielding layer was overlaid by the second recording layer.
It was impossible to recognize the numerals carried by the second recording layer 15 by observing the card under visible light directly through one of the major surfaces of the card. However, the five figure number was recognizable through the transparent adhesive layer and the transparent protective layer from the edge of the card.
EXAMPLE 11
In this example, an optical card was prepared in the same way as in EXAMPLE 9, except that a 2 mm×5 mm size pattern was drawn instead of the two stripes, and the shielding layer was provided on a side of the transparent substrate so that the shielding layer was overlaid by the second recording layer located inside the magnetic tape.
It was impossible to recognize the pattern of the second recording layer by observing the card directly through one of the major surfaces of the card under visible light. But the pattern was recognizable through the transparent adhesive layer and the transparent protective layer from the edge of the card.
EXAMPLE 12
This example describes the production of a magnetic tape provided with a protective layer and a second recording layer.
An aluminum reflective layer of thickness 1000 Å was formed on the back surface of the same magnetic tape used in EXAMPLE 9 by vacuum evaporation. Then at a position on the reflective layer corresponding to the edge of the card, bar code information was printed as the second recording layer 15 by screen printing the same two liquid setting type urethane acrylate ink used in the EXAMPLE 9. An ethylene metaacrylic acid hot-melt type adhesive (trade name: NUCREL (DUPONT-MITSUI POLYCHEMICAL CO. LTD.)) of thickness 5 μm was formed on the reflective layer so as to cover the second recording layer 15 with the adhesive layer 9 . The adhesive layer 9 had a transmissivity of 95% or more as to the visible light.
The optical card was prepared in the same way as in EXAMPLE 9, except that the magnetic film was used.
Observing the card under the visible light, it was possible to recognize the bar code through the transparent substrate 3 , the transparent adhesive layer 9 and the transparent protective layer 7 . On the other hand observing the optical card directly through the major surfaces of the card, it was impossible to recognize the second recording layer 15 .
EXAMPLE 13
This example describes the production of the optical card shown in FIG. 2 .
First, the production of a transparent protective layer 7 provided with a second recording layer 15 and a second shielding layer will be described.
A polycarbonate transparent substrate of area size 100 mm×100 mm, and thickness 0.3 mm was prepared. On a certain region of one side of the substrate a second protective. layer 15 comprised of two stripes of width 3 mm, and length 10 mm was printed using blue ink. Then a white ink (trade name: SERICOL 13-611 WHITE (Teikoku Printing Inks Mfg. Co. Ltd.)) as used in EXAMPLE 1, was printed on the whole second recording layer so as to cover the second recording layer 15 to prepare a 20 μm opaque layer of a transmissivity of 2% or less for visible light constituting the second shielding layer 19 .
The production of a transparent substrate 3 provided with the surface protective layer 11 , the first shielding layer 17 and the first recording layer 5 will now be described.
A polycarbonate transparent substrate of area 100 mm×100 mm, and thickness 0.4 mm was formed on one side with a preformat for an optical card. On the other side of the substrate 3 a urethane acrylate UV setting resin (trade name: UNIDIC (Dainippon Ink and Chemicals Inc.)) was spin coated to 4 μm thickness and hardened using a UV lamp (80 W/cm) to form a transparent hard coat layer constituting the transparent protective layer 11 . On an optical recording region of the preformat formed surface of the substrate a 3 wt % diacetone alcohol solution of 1,1,5,5,-tetrakis (diethxlaminophenyl) 1,2,4-pentadieniumperchlorate was coated by gravure coating and dried to form a layer of 1000 Å thickness forming the first recording layer 5 .
In order to produce the optical card, the prepared substrate 3 and the protective layer 7 were attached the same way as in EXAMPLE 1 so that the surface of the protective layer on which the second recording layer was not formed was directed towards the first recording layer 5 of the substrate 3 .
A two liquid setting type urethane acrylate silver ink (3 weight parts of a silver pigment ( 606 A) having a 3 μm average particle size and 1 weight part of HAC curing agent mixed with 10 weight parts of HAC ink medium; Seiko Advance Inc.) was prepared. Then, on the region of the surface protective layer 11 of the attached substrates corresponding to the position of the second recording layer 15 , the silver ink was printed using a 225 mesh screen block to form a layer 17 of thickness 20 μm constituting the first shielding layer. Then the substrates were die cut to form an optical card which had 85.6 mm×54 mm size.
Observing the side edge of the optical card adjacent the second recording layer 15 , it was possible to recognize the blue stripes through the transparent adhesive whose thickness was 60 μm and the transparent protective layer. On the other hand observing the optical card directly through the major surfaces of the card, it was impossible to recognize the second recording layer. | An information recording medium comprising a stack of layers includes a recording layer interposed between two shielding layers, the shielding layers being opaque to radiation within a predetermined wavelength band. The recording layer is adjacent to a layer which is transparent to radiation within the predetermined wavelength band, and is readable by radiation within the predetermined wavelength band passing into the layer through a free edge of the layer. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
This is a continuation of application Ser. No. 08/470,927, filed Jun. 6, 1995, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to visual bore hole logging. The visual examination of the bore hole for casing damage and/or fracturing and sediment stratification may be made with a video camera lowered throughout the bore hole and a video monitor in conjunction with a video cassette recorder for visualizing and recording the wall of the bore hole.
2. Description of the Prior Art
A well or bore hole is an artificial excavation made to extract water, oil, gas, and other substances from the earth. There is also the boring and drilling of holes for exploration. Exploration holes are drilled to locate mineral deposits such as oil and gas, ground water, geothermal supplies, to check for the integrity for nuclear waste depositories, and also to determine potential landslides in an unstable environment. Closed circuit TV camera systems are known in the art for visually examining the walls of a given bore hole. Additionally, in large diameter bore holes, a trained geologist can be physically lowered into the hole with a light source to visually examine the stratification, fracturing and layering of the various geological formations down through which the bore hole penetrates. In small diameter holes, this type of examination is impossible. Accordingly, in smaller diameter holes visual wall examination must be made with a moving picture bore hole camera or with a closed circuit television video camera. Furthermore, the heat, vapors, and fluids encountered in many bore holes make it dangerous for a trained geologist to be lowered down into the hole regardless of the diameter of the bore hole. In these types of bore holes, the geologist cannot be used, and the down hole video camera and tool must be employed.
Additionally, the bore shaft itself made by the bore hole is often not in a vertical orientation and has a drift or deviation in azimuth from its true vertical. There are drift recorders which monitor and log the slanting or drifting of the bore hole from its true azimuth. Inclinometers are known which determine deviation as well as drift, for example, by photographing from a plumb bob position against a compass background.
Additionally, while in the process of drilling a well and/or installing the steel tubing or casing to reinforce the wall of the bore hole, occasionally because of cave-ins, sedimentation and the like, the equipment in the hole becomes lodged and stuck therein. It then becomes a matter of locating the stuck pipe or other equipment in the wells. U.S. Pat. No. 2,817,808 issued to Giske, describes a method and apparatus for locating stuck pipe in wells.
After the steel casing or tubing has been in place for sometime in a well such as a ground water well, rusting and other shifts in the earth occasionally will cause rupturing or uncoupling of the steel casing. In this event, visual examination of the casing is necessary to see the extent of the break or leak and the feasibility of repairs.
Accordingly, the visual examination of the walls of a well are frequently needed when applied to the above problems.
SUMMARY AND OPERATION OF THE INVENTION
U.S. Pat. No. 4,855,820, issued on Aug. 8, 1989 to the present inventor, Joel Barbour, discloses an apparatus and method for visually examining the sidewalls of a bore hole. It includes a down hole video tool lowered into the bore hole by means of a cable and winch on the surface. The apparatus in U.S. Pat. No. 4,855,820 includes a wide angle video camera sealed and enclosed in its lower section. An upper section houses a power supply/triplexer, a telemetry board, an FM modulator video amplifier transmission board, gyro data interface board and a gyroscope for showing the directional orientation of the camera and apparatus in the bore hole. The gyroscope orientation and the visual image of the portion of the sidewall viewed is transmitted to a video display monitor in an equipment van on the surface. The image on the screen includes a directional reference point so that the direction of a portion of the sidewall being viewed can be ascertained. The camera images are recorded by a video cassette recorder for a permanent record of the visualization of the entire length of the bore hole. Various geological data can be extrapolated by this visualization by means of the observed and measured fracturing and stratification, which may be observed in a given bore hole. Additionally, the probe can be used to inspect bore holes previously encased by steel tubing to detect any leaks or other deterioration in the tubing or casing system.
The present invention is an improvement over the apparatus disclosed in U.S. Pat. No. 4,855,820. The present invention consists of a down hole video tool which includes an elongate, single section or two section cylindrical housing, which is lowered into the bore hole. The lower end of the tool houses a video camera, a wide angle video camera lens and a light source extending a few feet in front of the lens or around the lens to illuminate the dark interior of the bore hole. The lower portion of the tool also houses a second video camera, a narrow camera lens with a reflective mirror, or a periscope-shaped lens, and a light source positioned about 12 inches inboard from the probe end mounted wide angle camera. The second video camera is referred to as a side scan video camera. It is used to observe and record the walls of the bore hole adjacent to the side scan lens. There is a cut away area in the sidewall of the housing where the second light source is mounted, and a 45 degree angled mirror is also mounted in the cut away portion. The video camera and lens is positioned and sealed in the pressure housing so that the video camera lens faces the angled mirror. The reflected images of the bore hole on the mirror are picked up by the side scan video camera and transmitted to the surface. The mirror and cover for the light source are exposed to the elements. Everything else is contained within the pressure housing that protects the internal components from the high pressures, caustic fluids, vapors, and temperatures encountered at deeper depths in many bore holes. The side scan video camera is used to closely observe anomalies in the wall of the bore hole initially seen by the wide angle camera and lens at the lower probe tip of the tool.
Support equipment is located above ground, which includes a winch having a cable attached to the upper end of the tool to lower and retrieve the tool in the bore hole. The cable includes a bidirectional data transmitting cable and also an electric cable for providing a power supply to the tool itself. Typically, the winch is installed in a large equipment van used to transport the down hole video tool. Inside the van is a variety of support equipment including a television video monitor, a video cassette recorder, a video printer, telemetry equipment and a computer. A depth measuring device to indicate the position of the tool in the ground, and a temperature sensor to measure the ambient temperature at the location of the tool are also part of the equipment.
The down hole video tool has a leakproof, pressure, and temperature resistant housing which houses the end and side video cameras, the end and side light sources, a bidirectional telemetry circuit board for handling and processing the signals for transmission up to the television/video monitor above ground, video amplification means of the signals, a power supply/triplexer, and a gyro and/or inclinometer.
As the down hole video tool is traversed down hole through the bore hole, it is impossible to keep the camera and tool oriented in the same direction it was in when it was initially lowered into the bore hole. Unless restrained, there will always be a twisting or rotational effect by the down hole video tool to some extent as it twists on the supporting cable. As a result, the operator does not know the direction of a side of the wall being visualized on the video monitor by means of the images telemetered from either video camera in the hole. He is unable to tell the orientation or directional bearing of the camera in the hole, i.e., the operator cannot determine the north, south, east or west side of the bore hole displayed on the video monitor.
The present invention has been improved over the tool disclosed in U.S. Pat. No. 4,855,820. The present invention has an upper centralizer and a lower centralizer each spaced apart and mounted around the circumference of the tool. Both centralizers can be adjusted to fit the diameter of a particular bore hole to be logged. Both centralizers keep the tool centrally positioned in the bore hole. The centralizers prevent or limit the tool from rotating about the support cable while in the bore hole.
The term "tool" collectively refers to the support cable, cable head, and the two-section housing in which the electronics, the gyroscope and both cameras are mounted. The present invention also includes a means to rotate the lower portion of the tool to allow the side scan video camera to take a panorama view of the portion of the bore hole adjacent to the side scan video camera. The cable head section attached to the lower portion of the tool has the upper centralizer surrounding the cable and rotary driver motor mounted inside of it. The rotary driver has a coupler extending from the bottom of the cable head section so that the remainder of the tool with both video cameras can be demountably coupled to the rotary driver and cable section or assembly. The lower centralizer is bearing mounted around the lower portion of the tool. The lower centralizer allows the lower portion of the tool to rotate even when the lower centralizer is kept stationary and touching the wall of the bore hole to center the tool in the bore hole. The rotary driver in the cable section can be energized to cause the lower portion of the tool attached to it to rotate very slowly to allow the side scan camera to sweep the circumference of the side wall. The rotary driver can also be used to rotate the tool to position the side scan video at the fracture or break that needs to be closely observed. The rotary driver is a DC motor and is geared down so that it rotates the rest of the tool very slowly. Additionally, the coupler and driver are sealed in the upper portion to prevent damage from high pressures and caustic fluids. The upper portion with the driver does not rotate in the hole, because the upper centralizer prevents the upper portion from turning. The entire lower portion of the tool containing the gyroscope and video cameras turns as a unit when using the side scan video. Both centralizers are adjustable so that they can be expanded or contracted to fit into various sized bore holes. The cage-like centralizers can also be equipped with coil type expanders so that the centralizers can expand and contract in the bore hole to allow for changing diameters in the bore hole while conducting the down hole operation. In normal circumstances, the diameter is already known before hand. In that case, the centralizers are adjusted for that particular diameter before the operation begins.
In normal operation, the tool is lowered down hole through the bore hole to be logged or surveyed. Only the wide angle lens video camera and light source at the bottom probe tip of the tool are turned on and viewing the bore hole down hole as the tool passes through the bore hole. The two centralizers will prevent the tool from twisting on the cable while it is lowered down the bore hole. The tool will make only perhaps one or two rotations in a 2,000 foot bore hole. The centralizers prevent the tool from rotating in the bore hole. This eliminates the torquing on the cable by the tool.
The present invention incorporates a built-in free gyroscope in the housing of the tool. The gyroscope is about one and one-half inches in diameter and is arbitrarily selected to point north and then is "locked in" to always point north. The probe and cameras as part of the down hole video tool can rotate on the cable as a unit, but the spin axis of the gyro remains fixed in space. A reference point generated by the free gyro is displayed on the video screen to always indicate the directional orientation of the sides of the wall of the hole. The visual display on the video monitor screen will probably show the directional reference point drifting or floating around on the screen as the wide angle video camera in the housing rotates back and forth in the bore hole. Both video cameras are stationary in the tool. Directional orientation of either camera is indicated by the signal generated by the built-in gyro. The gyro generates a real time image dot displayed on the video screen above ground. The image dot is self-correcting to constantly show target heading of the camera, for directional reference of fractures, bed dip, casing damage or other objects being viewed by either the side scan video camera or the wide angle lens camera. The side scan video camera provides a close image of the side wall compared to the image generated by the wide angle lens. The user can get infinitely greater detail on fractures and bedding dips as the tool, with the side scan video, passes by. The user can get very precise measurements between the top and bottom of the bed dip or fracture, and the direction either one is lying along. Additionally, the side scan video camera is able to show the aperture of the particular fracture.
The greater resolution of the break in a casing in a bore hole provided by the side scan video camera allows the user to give a more informed opinion on the extent of damage to the casing, whether it is repairable, and how best to repair the fracture or break. The side scan video camera image on the video monitor above ground has a floating directional reference point displayed. The reference point is displayed and interpreted somewhat differently from the reference point displayed on the monitor from the wide angle lens, because only about 50 degrees of the side wall is visible at a time in the image and because the image shows the side wall from a horizontal perspective rather than from a vertical head-first perspective. The dot indicates the direction of the portion of the side wall being viewed. The top of the screen is north, the bottom of the screen is south, the left of the screen is west, and the right of the screen is east. The rectangular video screen should be viewed as if it were a 360 degree compass, with 12 o'clock, being due north, 3 o'clock being due east, 6 o'clock being due south, and 9 o'clock being due west. The directional reference point will change position in a circle fashion as the tool is rotated by the operator above ground. The dot will move to correspond with the imaginary clock positions. For example, if the dot is at the bottom of the video screen, the image on the screen shows the due south portion of the side wall. The gyroscope and the side scan video camera move together. They are synchronized with each other.
Video logs for the bore hole video examination are visually recorded on three-quarter inch video cassettes for a permanent record. These may then be copied onto VHS, Beta, or other formats for convenience. Also available in the equipment van are hard copies of video images produced by a video printer for immediate presentation, and a video typewriter for recorded commentary. The commentary is recorded on the videotape. The orientation has applications to show hard rock fracture sizing and orientation. For example, the layer of the fracturing can be visually observed and measured by the image on the video screen. If the fracture is inclined, then the angle of inclination can also be extrapolated by a standard trigonometric function by knowing the diameter of the bore, and the difference in height between the top of the fracture at one side of the bore hole and the top of the fracture at the opposite side of the bore hole. The difference in height would form the vertical leg of a right triangle and the diameter would be the horizontal leg of the right triangle. These two numbers could be used to calculate the tangent to find the angle of inclination of the fracture at that particular depth. The reference point showing the true north on the video display monitor would also show the direction of the slope of the fracture line, or bed dip.
The above ground winch which lowers the cable down hole into the well bore hole has an optical encoder and a calibrated wheel on the winch. This measuring equipment displays on the video monitor the depth of the tool within a tenth of a foot or even less. The depth measurements, or differences in the depth measurements can be made precisely using the side scan video. For example, in an average 8 inch diameter hole, the difference in height in the top of the fracture on opposite sides of the hole is three to eight inches. This can easily be determined by looking at the depth reading presented on the video screen at the top of the fracture while the tool is being lowered to the top of the fracture on the other side of the hole and noting or reading the difference in the depth, usually in inches, as shown on the visual display. The image generated by the side scan a video immediately indicates on the screen the compass direction of the fracture. The video camera can be rotated to show the opposite side of the fracture. One can raise or lower the tool to measure or calculate the height difference of the fracture. The sloping direction requires two compass readings; one at the top of the fracture having the shallower depth, and the other at the top of the same fracture having the deeper depth.
One could drill an array of exploration bore holes in a given surface area and then map the fractures and stratifications of the underground formations to determine the geological makeup of that given area. In the event where the bore holes are slightly inclined, then the readings from a previously inserted inclinometer could be used as a factor to determine the true angle of inclination of the layers. Or an inclinometer could be used by attaching it to the tool so that all readings could be taken simultaneously.
Accordingly, it is an object of this invention to have a down hole video tool for down hole passing through the length of a drilled bore hole, and having a wide angle video camera mounted at the probe tip of the tool for visually observing the walls of the bore hole, and a second side mounted video camera for close-up inspection of a portion of the side wall. Both are used in conjunction with a gyroscope in the tool so that the compass directional orientation of either the camera lens will be known when the data is telemetered up to the video screen monitor in the equipment van. One sees a directional reference point on the video monitor screen to determine the directional orientation shown of the bore hole walls when viewed on the video monitor. The directional reference point provides further data so that one can observe and calculate the rising or dropping angle of any fragmentation, bed dip, or layered rock in the bore hole. The directional indicator also informs one of the direction of leakage in a cased bore hole. The side scan video camera provides precise information about the anomalies usually encountered in the walls of a typical bore hole. The side scan can precisely measure bed dip.
It is an additional object of this invention to provide a down hole video tool that can be rotated at a given location in a bore hole to allow a side mounted video camera to take a panorama view of a section of the side wall, and also to orient the side scan video camera directly at an anomaly in the side wall of the bore hole.
It is a further object of this invention to provide a down hole video tool having a pair of centralizers for centering the tool in the bore hole and for preventing the tool from rotating while in the hole. The lower portion of the tool can be rotated by a rotary driver mounted in the cable head when using the side scan video camera. The tool includes a video camera with wide angle lens in a cylindrical housing forming the lower head section, and an upper section including a cylindrical housing for a power supply/triplexer to power the components, a free gyroscope to indicate the designated reference point of the camera lens, a means for video transmission of the data up to the video display monitor and a telemetry board for handling all of the data inputs and power sources to bidirectionally transmit the data to the surface. These are part of the second section of the tool.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the schematic figure of the equipment van stationed above ground and feeding the side scan down hole video tool into the bore hole by means of a winch. The bore hole having a casing is schematically shown in cross section with a fracture in the casing.
FIG. 2 is an enlarged view of the oval-shaped line 2 in FIG. 1 where the upper section is held stationary and centered in the bore hole by the upper centralizer, and the lower section is rotatably connected to the rotary driver in the upper section.
FIG. 3 is an enlarged view of the oval-shaped line 3 in FIG. 1 where the lower section is centered by the lower centralizer having sealed bearings for allowing the lower section to rotate, and the wide angle video camera lens and light source at the bottom tip of the tool is viewing the side wall at that place and is transmitting the images to the display monitor in the van above ground.
FIG. 4 is similar to FIG. 3 and illustrates the side scan video camera lens and light source in operation to visually examine the fracture found in a portion of the side wall at that particular location. It is transmitting the images to the display monitor in the van above ground while the lower section is being slowly rotated about its axis to position the side scan camera at the correct angular orientation for viewing the fracture head on. An angled mirror adjacent the video camera reflects images from the hole to the camera lens.
FIG. 5 illustrates a typical example of what is seen on the video screen of the monitor in the equipment van when the side scan video is transmitting images. The side scan camera is used to detect and observe fractures in the bore wall as illustrated in FIG. 5. The directional reference dot is also shown on the video display.
FIG. 6 illustrates an alternate embodiment of the side scan video camera. In this alternate, the angled mirror is eliminated and the side scan video camera and its lens are side-mounted so that the camera is looking directly at the side wall. The lens can be equipped with a power zoom and iris adjustment to compensate for large or small diameter bore holes. These features can be controlled from above ground. The iris adjustment adjusts the amount of light being picked up by the camera.
FIG. 7 illustrates the side view of the side-mounted video camera illustrated in FIG. 6 and the rotational ability of the tool.
FIG. 8 illustrates the video tool in an exploded view. The upper section is rotatably attached to the cable head. The upper section houses the gyroscope, gyro-data interface, power supply/triplexer, telemetry board, and video amplifier transmission board. The wide angle video camera and the side mounted video camera are in the lower section along with their respective adjacent light sources. The upper and lower sections are for ease in transporting the tool to the job site. The upper and lower sections could be one piece if desired.
FIG. 9 illustrates the location of the two video cameras, the location of the two stationary centralizers, and the rotation of the coupled upper and lower sections relative to the stationary cable head assembly.
FIG. 10 illustrates a typical example of what is seen on the video screen of the monitor in the equipment van. There is shown visually the horizontal section of the wall of the bore hole at a particular location, the temperature at that particular location and the depth of the tool at that particular location. There is also shown the "floating" directional reference point showing the north direction of the wall at that location.
FIG. 11 is a acetate overlay which can be placed on the screen of the video monitor to find the direction of a section of the visualized wall relative to the directional reference dot shown on the video display.
FIG. 12 is an enlarged fragmentary vertical cross section of the subsurface wherein the light source is shown ahead of the wide angle camera lens and in turn, the wall of the bore is being visually examined by means of viewing it on the display screen of the monitor in the equipment van. The video camera picks up the light reflections and transmits them via coaxial cable for display on the video screen monitor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is disclosed in phantom lines the equipment van 2, which is used to store and transport the equipment to the job site. The van equipment includes a winch 4, which has a cable 6 attached to the down hole video tool 8, which is shown inside the bore hole 10. The bore hole to be visually monitored can be any hole previously excavated or drilled. The instrumentation inside the equipment van includes a video monitor 12 having a rectangular display screen 14, a video cassette recorder 16, a video printer 18 and a telemetry key board video typewriter 20. The cable 4 and cable head 3 serve several purposes: for example, (1) to raise and lower the video tool 8; (2) to connect the tool 8 with the instrument panel 5 to bidirectionally relay the video transmissions by means of a coaxial cable or fiber optic cable, and (3) to provide a cable to supply electricity to the tool. The down hole video tool generally has an upper section and a lower section, also referred as a second housing and a first housing respectively. The upper section 30, the second housing, houses the gyroscope 32, the gyroscope data interface 34, the power supply/triplexer board 36, the telemetry board 38, and the FM modulation amplifier video transmission board 40. The lower section 50, the first housing, houses the wide angle video camera 52, the wide angle lens 54, the light source 60, the side mounted video camera 200, the lens 210, the side light source 220, and various connecting cables 48.
The primary power supply is designed to accept wide ranging incoming DC voltage anywhere from 40 to 150 volts. It takes the incoming variable DC to the tool light sources. Either lamp 60 or 220 is capable of receiving 40 to 150 volts. There are also several regulated DC voltages to run both cameras; perhaps 20 volts to either camera. A camera and light switching means is illustrated in phantom lines in FIG. 8 as a switch 230 and 4 cables (not illustrated) with D connectors connected to both cameras and lights. The tool has the capability of having both lights and both cameras energized at the same time. However, the switch 230, allows the operator on the surface to turn off one camera and light and then turn on the other camera and light in order to minimize power consumption. The DC voltages also run the gyro, both cameras, VC handling, telemetry coordination and the plotting to the gyro. Either camera has a reliable bidirectional telemetry system. It is a microprocessor controlled system.
Attached to the head of the tool where the video camera is located is a light source 60 which shines and illuminates the sidewalls so that the video camera can pick up the light reflections from the sidewall as it is being passed down hole through the bore hole. The light source, if desired, could be circular and concentric with the camera lens. The images picked up by the video camera 52 are processed and fed through the electrical components inside the housings of the tool. The signal is passed to the surface by a conductor coaxial cable or fiber optic cable, which carries video and sub-carrier frequencies bidirectionally. It is also called a coaxial data transmission line. The electronic components in the second housing 30 section or compartment of the tool process and transmit bidirectionally a variety of electronic data.
The side mounted camera 200, like the camera 52, has its images processed and fed through the electrical components inside the housings of the tool. The signals are passed to the surface by a conductor coaxial cable or fiber optic cable 6.
There is a modular inclinometer available, which may be added to the gyroscope 32 inside the protective tube 33. The modular inclinometer can be coupled to the gyroscope so that both transmit data together. When the inclinometer is coupled to the gyroscope, it is not shown in the drawings, because it is contained within the protective tube 33.
The gyroscope directional orientation is also incorporated in the signals transmitted from the tool to the equipment inside the equipment van. The end result is a video display 14 as illustrated in FIGS. 5 or 10. FIG. 10 shows what a typical visual display from the wide angle camera 52 looks like in actual operation. One sees the three prongs 62 and the backside ring 64 supporting the light source 60 positioned in front of the video camera 52 and camera wide angle lens 54. The lithography of the sidewalls of the bore hole 10 is readily apparent because the light source reflects light off the sidewalls which in turn is picked up by the camera. The wide angle video camera 52 shows a rectangular screen display as shown in FIG. 10 having a conventional scanning capability of approximately 270 horizontal lines on the screen. The video camera 52 remains stationary with the tool, i.e., if the entire video tool rotates or twists back and forth as it is being lowered into the bore hole, then the camera will rotate a like amount. It is usually impossible to prevent any twisting movement of the camera in this type of operation. As a result of the twisting and turning on the cable 6, the orientation of the camera 52 and lens 54 relative to the sidewall of the bore hole cannot be ascertained unless a directional reference point is created relative to the camera. This is accomplished by having a built-in gyroscope 32 inside the second housing comprising the upper section 30 of the tool so that even if the housing tool rotates by twisting on the cable, the spin axis of the gyroscope will still be aligned to a certain reference point which is usually arbitrarily selected as the true north. The north reference point can be seen in FIG. 10 as an off center dot 66. One can determine where the south side of the sidewall is by going 180 degrees from the true north reference point 66 displayed on the monitor. As the tool turns on the cable while it is being lowered in the hole, the reference point will move about or float on the video screen. However, everything is still relative to the reference point to the true north such that one can always determine the direction of a particular portion of the sidewall of the bore hole by means of the directional reference dot. The directional orientation is important in several matters especially when observing the fracturing and layering of the soils through which the bore hole is drilled. For example, FIG. 12 shows a cross-sectional view of a typical layered stratigraphic formation with a fracture in the subsurface area. As can be seen in FIG. 4, there is a fracture 70 and layering 90. The layering is inclined to indicate that the layering is not always horizontal but is quite often inclined or slanted as a bed or layering in the subsurface. The angle and direction of this angled fracturing or stratification can be calculated by taking data from the video screen as shown in FIG. 5 or FIG. 10. For example, the difference in the height of the fracturing can be observed on the display, which reads the depth of either camera in tenths of feet, and also how the orientation of the fracturing is slanted for example from north to south, or east to west. The difference in the height between the top 80 and 82 (FIG. 12) of a layer at opposite sides of the bore hole can be measured by taking the difference in the two depth readings on the display as either camera lens passes 80 and 82.
The side mounted video camera 200 allows for a very precise observation and measurement of the layering or fracture compared to the resolution available from the wide angle video camera 52. In normal operation, only the wide angle camera 52 and light source 60 is energized while surveying a bore hole. Fractures and bed dips will be picked up by the camera 52. If a particular fracture or anomaly needs to be examined in more detail, the side video camera 200 and light source 220 are switched on and the wide angle camera 52 and light 60 are switched off. The two camera lenses 210 and 54 are about 15 inches apart. The operator can observe the depth on the video screen in one-tenth inch increments where the wide angle lens is adjacent to the anomaly. The operator then further lowers the tool an additional 15 inches until the side scan lens is at the same depth as the anomaly to be viewed. The lens 210 of the side scan camera 200 has a fairly intense image. It has about a 50 degree field of view diagonally. Unless the lens is pointing directly at the anomaly, the tool has to be rotated until the lens is pointed directly at the anomaly. The is accomplished by the operator energizing the rotary driver 300 in the cable head assembly 3. The cable head assembly 3 remains stationary and will not rotate while in the bore hole, because the first centralizer 320 prevents the cable head assembly from rotating. Additionally, the second centralizer 400 surrounding the lower portion of the tool keeps the tool centered in the hole. The second centralizer has upper 410 and lower 420 sealed bearings to allow the tool to rotate while the second centralizer 400 remains stationary in the hole. The sealed bearings 410 and 420 are self-lubricating and are not subject to jamming or damage while in the bore hole. The rotary driver turns the tool counterclockwise until the lens is viewing the anomaly directly. The top of the second housing 30 has a coupler 27 that demountably couples to the end of the rotary drive 300. This connection has to be rotatable, but it must also be sealed tightly to prevent any leakage into the cable head 3 or the housing 30 from the environment usually encountered in the bore hole. The DC motor that turns the rotary driver 300 receives its DC power supply from the switche 230 in the housing 30. The switch 230 converts line power to DC voltage from 50 volts up to 150 volts. The operator can also raise or lower the tool to precisely measure the difference in heights of the slanting layer of the bed dip. The diameter of the hole and the difference in the height allows one to calculate the slope created by the hypotenuse of the right triangle to determine the inclination of that particular fault line. This can easily be calculated by using basic trigonometry or algebra to arrive at the angle of inclination or declination of that particular fault. By means of mapping vertically the series of layers and other geologic formations that are frequently encountered through a bore hole, one can create a geological profile of the type of rock formations in that particular area and at that particular hole. One can then drill an array of similar holes in that area and then by mapping the layering effects in the various holes, one could arrive at a geological profile of that given area by means of visualizing the various rock and sedimentary layers and also their inclination points. This is extremely useful in oil and gas exploration where the geologists are looking for synclines and anticlines, or dome shaped underground impermeable rock formations which are generally required in order to trap any possible oil and gas deposits so that they could be drilled at the apex of the dome of the anticline.
The visualization of the bore hole is quite useful when looking for geothermal deposits in the sense that the camera can visually observe the hole itself to see the type of layered rock formations and to observe the often sought-after information visually shown on the screen as shown in FIGS. 5 and 10. The upper left hand corner of the video display in FIG. 10 displays the degrees in Fahrenheit reading 63 where the tool is located. The tool has two built-in thermal sensors for continuous surface readout of tool and hole temperature. The pressure and temperature resistant housing comprising the tool has the ability to withstand heat up to 200 degrees Fahrenheit. However, when viewing a bore hole for potential geothermal use, the heat could damage the instrumentation in the housing. Accordingly, the temperature is used mainly as a safety factor to prevent damage to the video tool. As previously stated, the other set of numbers 67 shown on the video display screen in FIG. 10 indicates the depth in feet of the video tool.
FIGS. 2-4 show a section of a bore hole. It is nearly impossible to drill a perfectly vertical hole because of the diverse geologic formations encountered by the drill bit. Occasionally the drill hole or the bore hole is intentionally slanted in a given direction to reach a proposed source of oil and the like. However, the slanting of the bore hole can be readily determined by instruments already known in the art. A typical instrument is known as an inclinometer (not shown) which indicates and records the orientation of the tool or drill away from the vertical. In one type of inclinometer this can be done by sequentially taking photographs of a plumb bob in conjunction with a compass. In that way, the angle of inclination and the direction of the deviation of the bore hole can be extrapolated in conjunction with the video display to accurately describe the deviation from vertical and the condition of the sidewall of the bore hole at any given location. However, the depth reading 67 is a function of the amount of cable let out from the surface. The deviations from the true vertical would create a longer length of cable than the true depth because of the deviation from the true vertical. This could be factored to subtract the reading of the depth of the tool to arrive at the depth of the tool in the true vertical should that number be required.
FIG. 9 shows a situation where the bore hole is not truly vertical and this is evidenced by the center of the ring 64 for the light source not being in the center of the hole. This is only illustrated as an example of what is occasionally encountered in actual field conditions. One can quickly make a printed record at any given location of the tool by means of the video printer 18 connected to the video display monitor 12. Immediately, one can have a record of the bore hole at that particular location displayed on the screen 14. The master video log which is a video tape of the sidewalls along the entire length of the well bore hole examined, can be duplicated to have several copies made from the master video log for distribution to interested personnel for their evaluation and for their use of the data found by the video tool. One can take the acetate compass overlay 100 as shown in FIG. 11 and overlay it on the video display screen to quickly determine the true orientation of a particular section of the sidewall image shown on the video screen.
The center of the compass 102 (acetate overlay) is matched up with the dot 67 for the depth. The north arrow 104 is aligned with the north gyroscope dot 66 on the display 14. Now the directional bearings of the entire wall can readily be determined.
The two sections comprising the video tool, the second housing having the electronic components and gyroscope, and the first housing having the two cameras are coupled sections having interlocking pin 51 and hole 31 so that when they are connected together, the gyroscope will always be in the same orientation as the camera is. The upper and lower section of the tool can only be assembled or coupled in a preset configuration. When a job is initially begun, the gyroscope must be "zeroed" in to a fixed directional reference which is normally the true north. This is accomplished by having an assistant standing several hundred feet away with a survey sight line pointing to the true north and by means of a tripod or transit the true north is accurately determined. In turn, the gyroscope 32 which is caged in the housing 30 is adjusted so that its reference point 66 is set to the true north. The gyroscope in its uncaged position will always point to the true north even when the earth is rotating. It is a well known scientific principle that the axis of a free gyroscope will remain fixed with respect to space. When doing a well logging operation of a few hours the degree of offsetting of the true north from the gyroscope image on the video display is not important because of the minor change in orientation caused by the rotation of the Earth. However, where the operation takes several hours to do, the reference point 66 indicated as north on the video screen must be adjusted to compensate for the rotation of the earth. This has to be taken into consideration when the accuracy of the true north bearing is very important on a particular job.
When the tool is placed in the bore hole to be mapped or surveyed, the gyroscope 32 must first be zeroed in to the true or magnetic north. This is accomplished by performing the following sequential steps.
The gyroscope is energized for 5-10 minutes to allow it to come up to its operating speed of 40,000-50,000 RPM. The gyroscope is in a caged position, i.e., it is not free to float independently of the housing 30 in which it is contained. After the gyroscope has come up to operating speed, the down hole video tool 8 is placed in the bore hole 10. A surveyor's tripod or transit with a sight marker is placed as far away as possible, but at least 100 feet away from the bore hole and without any magnetic interferences. A sighting telescope (not shown) is demountably attached to the top of the end of the cable head 3. The telescope is sighted in with the sight marker and tripod or transit previously placed some distance away from the gyroscope. Usually, north will be the arbitrary directional reference point. However, east, west, south, or any direction could be used as a reference point if so desired. In this configuration there is a mark 7 or reference point on the outside cable head 3 indicating the north position for the gyroscope. The down hole video tool while hanging pendulant in the bore hole to be surveyed, is rotated until the north marker 70 on the outside of the housing comprising the cable head 3 aligns with the true north as sighted in with the sight marker. This can be accomplished by physically rotating the cable head which is interlocked with the attached tool so that the marker 7 aligns with the north according to the sighting with the tripod. When the mark 7 is aligned with the true north, there is a switch in the telemetry equipment 20 inside the equipment van which is switched on. This telemetry switch will uncage the gyroscope and allow it to float in a free position. The spin axis of the free gyroscope then will always point to the north direction. When the gyroscope is in the free-floating position it will always point towards north regardless of the rotation of the earth. This information is processed and displayed on the video display as the "floating" north directional reference dot 66.
During the switching on of the telemetry machine 20 to uncage the gyroscope to the free-floating position, the time is also entered into the telemetry equipment by means of the video keyboard. After the bore hole surveying has been completed, the tool is again pulled to the surface and the true north position of the marker on the housing indicating the direction of the gyroscope is again set and again entered into the telemetry equipment. The time of the day is also entered. In a surveying operation taking an hour or so, the drift caused by the rotation of the earth is negligible. However, in a more extended surveying operation extending over 3-4 hours, the drift could comprise 3-4 degrees drift. This drift caused by the earth's rotation will then be entered into the telemetry and processing equipment. The reference point displayed on the screen is corrected based upon the time vs. drift parameters (However, depending upon the characteristics of the particular gyroscope employed, drift from internal friction in the gyroscope itself may exceed any drift due to earth rotation).
The two video systems enclosed in the lower portion of the tool are specially designed high resolution black and white or color video system for down hole use. The tool's depth capacity is 10,000 feet with a 2.150 inch outer-diameter for black and white and a 3.5 inch outer diameter for color. The array of cables exposed at the end of the housing 50 are coaxial cables for the camera, and also a power supply cord for the camera and light source 60. These cables 48 connect with the electronic components enclosed in the second housing 32.
The greater resolution of the break in a casing in a bore hole provided by the side scan video camera 200 allows the user to give a more informed opinion on the extent of damage to the casing, whether it is repairable, and how best to repair the fracture or break. The side scan video camera 200 image on the video monitor, FIG. 5, above ground has a floating directional reference point 73 displayed. The reference point is displayed and interpreted somewhat differently from the reference point 66 of FIG. 10 displayed on the monitor from the wide angle lens, because with the side scan video camera only about 50 degrees of the side wall is visible at a time in the image and because the image shows the side wall from a horizontal perspective rather than from a vertical head-first perspective. The dot indicates the direction of the portion of the side wall being viewed. The top of the screen is north, the bottom of the screen is south, the left of the screen is west, and the right of the screen is east. The rectangular video screen should be viewed as if it were a 360 degrees compass, with 12 o'clock, being due north, 3 o'clock being due east, 6 o'clock being due south, and 9 o'clock being due west. The directional reference point will change position in a circle fashion as the tool is rotated by the operator above ground. The dot will move to correspond with the imaginary clock positions. For example, if the dot is at the bottom of the video screen, the image on the screen shows the due south portion of the side wall. The gyroscope and the side scan video camera move together. They are synchronized with each other.
The side-mounted side scan video camera is shown in FIGS. 6 and 7. The camera 200 and the lens 210 are to be pointed directly at the side wall. This minimizes any distortion. Also it eliminates the reverse imaging problems caused by the reflective mirror of the embodiment of FIG. 4. In the embodiment of FIGS. 6 and 7, the side scan video camera 200 is side mounted. Specifically, the side scan video camera 200 includes a side mounted sensor circuit board 200a supporting a planar image sensor (such as a CCD integrated circuit) facing the lens 210 and a side window 224 in the housing. The sensor circuit 200a may be connected to the other circuits of the side scan video camera 200 via a ribbon cable 200b. The lens can also have a power zoom feature to refocus the lens to compensate for varying diameter bore holes. This eliminates the need to place a particular focus lens before starting the survey operation. An additional option on the camera lens is an aperture control for the iris to control the amount of light being picked up by the camera. Occasionally, the light from the light source 220 floods out the image. The iris control can correct this problem whenever it is encountered. A quartz window 224 seals and protects the lens compartment from the elements encountered in the bore hole. The light source 220 is protected by a quartz dome 226. The lower portion of the tool as illustrated in FIGS. 3, 4 and 8 shows segments coupled together. The bottom segment 440 contains the wide angle camera and light source. The middle segment 450 contains the side scan camera 200 and light source 220. The segments are for convenience so that they can easily be separated for maintenance or repair. However, the entire tool could be a one piece tubing if desired.
In the embodiment of FIGS. 3 and 4, the image sensor of the side scan camera 200 and the lens 210 both face down hole rather than sideways, so that a 45-degree angled reflective mirror 215 is required to provide a side view to the lens 210 and camera 200. Alternatively, the angled reflective mirror 215 could be replaced by a periscope-shaped lens.
A flux gate north directional seeker could be substituted for the gyroscope. An inclinometer could be attached to the tool to get directional slope of the bore hole. Usually, however, the bore hole to be surveyed and video logged, has already been logged with an inclinometer, and the data is used in conjunction with the video logging.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that the full scope of the invention is not limited to the details disclosed herein, but may be practiced otherwise than as specifically described. | An apparatus and method of visually examining the sidewalls of a bore hole include a down hole video tool lowered into the bore hole by means of a cable and winch on the surface. The apparatus includes a wide angle end video camera positioned at the tip of a lower section and a rotatable side scan video camera mounted inboard from the end video camera. The end video provides a panorama view of a portion of the bore hole, and the side scan video camera provides a detailed close-up 360 degree view of a portion of the bore hole. An upper section houses a power supply/triplexer, a telemetry board, an FM modulator video amplifier transmission board, gyroscope data interface board, and a gyroscope for showing the directional orientation of either camera and apparatus in the bore hole. The gyroscope orientation and the visual image of the portion of the sidewall viewed is transmitted to a video display monitor in an equipment van on the surface. The image on the screen includes a directional reference point so that the direction of a portion of the sidewall being viewed can be ascertained. The camera images are recorded by a video cassette recorder for a permanent record of the visualization of the entire length of the bore hole. The tool is used to inspect exploratory bore holes, or bore holes previously encased by steel tubing to detect any leaks or other deterioration in the tubing system. | 4 |
TECHNICAL FIELD
[0001] The present invention relates to a honeycomb catalyst for purifying exhaust gas discharged from an internal combustion engine, and particularly, relates to a honeycomb catalyst for use in SCR (Selective Catalyst Reduction) for reducing NOx in the exhaust gas.
BACKGROUND ART
[0002] Heretofore, as one of systems which purify exhaust gas of an automobile, there has been known an SCR system that reduces NOx to nitrogen and water by using ammonia. In this SCR system, a honeycomb unit, in which a large number of through holes allowing the exhaust gas to pass therethrough are provided in parallel in a longitudinal direction, is used as an SCR catalyst carrier, and for example, one is known, which is formed by performing extrusion molding for materials which contain zeolite as a main raw material. In this case, as the zeolite, there are used SAPO (silicoaluminophosphate), β zeolite, ZSM-5 zeolite, and the like.
[0003] In the honeycomb catalyst using zeolite, it is known that strength thereof cannot be maintained sufficiently when an amount of zeolite is increased, and for reinforcement of the honeycomb catalyst, it is proposed to mix and use Al 2 O 3 and the like as inorganic particles (for example, refer to Patent Documents 1 and 2). In Patent Document 1, a honeycomb structure is disclosed, which attempts to enhance strength thereof by containing Al 2 O 3 therein in a predetermined ratio. Moreover, in Patent Document 2, as one that aims to enhance heat resistance and durability in a case of being used as the SCR catalyst carrier, zeolite with a CHA structure is disclosed, in which a composition ratio of SiO 2 /Al 2 O 3 is less than 15, and a particle size is 1.0 to 8.0 μm.
PRIOR ART DOCUMENTS
Patent Documents
[0004] Patent Document 1: WO 2009/141888 A1
[0005] Patent Document 2: JP 2010-519038 A
SUMMARY OF INVENTION
Technical Problem
[0006] However, if the zeolite with the CHA structure, which serves as the raw material, is directly extruded to foul′ the honeycomb, then in a manufacturing process, a crack has sometimes occurred in the honeycomb since the zeolite with the CHA structure has a linear expansion coefficient, of which absolute value is as large as approximately −5×10 −6 , and has large expansion/shrinkage (water absorption displacement) due to water absorption/desorption.
[0007] The present invention has been made in consideration of the above-described conventional problems, and it is an object of the present invention to provide a honeycomb catalyst, which is capable of suppressing such an occurrence of the crack by reducing the linear expansion coefficient and the water absorption displacement while highly maintaining the purifying performance of NOx.
Means for Solving Problem
[0008] The present invention that solves the above-described problems is as follows.
[0000] (1) A honeycomb catalyst including a honeycomb unit in which a plurality of through holes are provided in parallel in a longitudinal direction while being separated from one another by partition walls,
wherein the honeycomb unit contains at least two types of inorganic particles and an inorganic binder,
the inorganic particles contain: zeolite having a CHA structure, in which a composition ratio of SiO 2 /Al 2 O 3 is less than 15; and an oxide other than the zeolite, the oxide having a positive linear expansion coefficient, and
a ratio (X:Y) of a volume (X) of the zeolite and a volume (Y) of the oxide is 50:50 to 90:10.
[0009] The oxide having the positive linear expansion coefficient is mixed with the zeolite having a negative linear expansion coefficient, whereby the honeycomb catalyst of the present invention achieves cancellation between both of the linear expansion coefficients, and can suppress a linear expansion coefficient of a whole thereof within a range of ±4.0×10 −6 . Therefore, at the time when the honeycomb catalyst is used, the crack can be suppressed from occurring. In the zeolite according to the present invention, if the composition ratio of SiO 2 /Al 2 O 3 thereof exceeds 15, then a purification rate for NOx is lowered. A reason for this is that an amount of Cu that functions as a carriable catalyst becomes small if SiO 2 /Al 2 O 3 is high.
[0000] (2) The honeycomb catalyst according to (1) described above, wherein an average particle size of the zeolite is 0.1 to 1.0 μm, and an average particle size of the oxide is 0.01 to 5.0 μm. The average particle size of the zeolite and the average particle size of the oxide are set within the above-described ranges, whereby contacts points between the particles are increased to enhance strength, and further, a pore size can be adjusted to a range suitable for purifying NOx.
(3) The honeycomb catalyst according to either one of (1) and (2) described above, wherein a ratio (B/A) of the average particle size (A) of the zeolite and the average particle size (B) of the oxide is 1/10 to 5. The contact points between the particles in which the ratio (B/A) of the average particle size (A) of the zeolite and the average particle size (B) of the oxide is within the above-described range are increased to enhance the strength, and further, the pore size can be adjusted to the range suitable for purifying NOx.
(4) The honeycomb catalyst according to any one of (1) to (3) described above, wherein Cu is carried on the zeolite, and a carried amount of Cu is 3.5 to 6.0 wt % with respect to the zeolite. Cu is carried on the zeolite by 3.5 to 6.0 wt %, whereby high NOx purifying performance is obtained by means of a small amount of the zeolite. In a case where such a content of Cu is less than 3.5 wt %, then the NOx purifying performance is sometimes lowered, and in a case where the content of Cu exceeds 6.0 wt %, then ammonium oxidation is accelerated at a high temperature, and the purifying performance for NOx is sometimes lowered.
(5) The honeycomb catalyst according to any one of (1) to (4), wherein the oxide is at least one selected from the group consisting of alumina, titania and zirconia. In the honeycomb catalyst of the present invention, the oxide just needs to have a positive linear expansion coefficient, and specifically, at least one selected from the group consisting of alumina, titania and zirconia is preferable.
(6) The honeycomb catalyst according to any one of (1) to (5), wherein the ratio (X:Y) of the volume (X) of the zeolite and the volume (Y) of the oxide is 60:40 to 85:15. If the volume ratio of the zeolite and the oxide stays within the above-described range, then it becomes possible to enhance the strength of the honeycomb unit and adjust the pore size while maintaining the purifying performance for NOx.
(7) The honeycomb catalyst according to any one of (1) to (6), wherein the zeolite is contained by 150 to 350 g/L with respect to a whole of the honeycomb unit. If the amount of the zeolite is larger than 350 g/L, then displacement of the honeycomb unit, which may be caused by expansion/shrinkage of the zeolite due to water absorption/desorption, is prone to occur, and if the amount of the zeolite is smaller than 150 g/L, then the NOx purifying performance is lowered. The amount of the zeolite is adjusted within the above-described range, whereby such water absorption displacement is reduced, and the purifying performance for NOx can be maintained to be high.
(8) The honeycomb catalyst according to any one of (1) to (7), wherein a density of through holes on a cross section perpendicular to the longitudinal direction of the honeycomb unit is 62 to 186 pcs/cm 2 , and a thickness of the partition walls of the honeycomb unit is 0.1 to 0.3 mm. The density of the through holes and the thickness of the partition walls in the honeycomb unit are set within the above-described range, whereby high NOx purifying performance can be obtained.
(9) The honeycomb catalyst according to any one of (1) to (8), wherein the honeycomb catalyst has a columnar shape in which a diameter is 140 to 350 mm and a length is 75 to 310 mm. The honeycomb catalyst of the present invention is formed into a columnar shape with such sizes as described above, and is thereby suitable for a case of being mounted on an automobile.
Advantageous Effect
[0010] In accordance with the present invention, there can be provided the honeycomb catalyst, which is capable of suppressing the occurrence of the crack by reducing the linear expansion coefficient and the water absorption displacement while highly maintaining the purifying performance of NOx.
BRIEF DESCRIPTION OF DRAWINGS
[0011] FIG. 1 is a perspective view schematically showing an example of a honeycomb catalyst of the present invention;
[0012] FIG. 2 is a perspective view schematically showing another example of the honeycomb catalyst of the present invention; and
[0013] FIG. 3 is a perspective view schematically showing an example of a honeycomb unit that composes the another honeycomb catalyst of the present invention.
DESCRIPTION OF EMBODIMENTS
[0014] A honeycomb catalyst of the present invention is a honeycomb catalyst including a honeycomb unit in which a plurality of through holes are provided in parallel in a longitudinal direction while being separated from one another by partition walls, characterized in that the honeycomb unit contains at least two types of inorganic particles and inorganic binder, the inorganic particles contain: zeolite having a CHA structure, in which a composition ratio of SiO 2 /Al 2 O 3 is less than 15; and an oxide other than the zeolite, the oxide having a positive linear expansion coefficient, and a ratio (X:Y) of a volume (X) of the zeolite and a volume (Y) of the oxide is 50:50 to 90:10.
[0015] Hereinafter, a description will be made in detail of respective components which compose the honeycomb catalyst of the present invention.
Inorganic Particles
[0016] In the honeycomb catalyst of the present invention, the inorganic particles contain at least two types, and the two types of inorganic particles are: the zeolite having the CHA structure, in which the composition ratio of SiO 2 /Al 2 O 3 is less than 15; and the oxide other than the zeolite, the oxide having a positive linear expansion coefficient. Hereinafter, the respective inorganic particles will be described.
[0017] Zeolite
[0018] The zeolite according to the present invention is zeolite having the CHA structure, in which the composition ratio of SiO 2 /Al 2 O 3 is less than 15 (hereinafter, the zeolite is also referred to as “CHA zeolite).
[0019] The zeolite according to the present invention is zeolite, which is named CHA as a structure code and classified thereby in the International Zeolite Association (IZA), and has a crystal structure equivalent to that of chapazite produced naturally.
[0020] Analysis of the crystal structure of the zeolite can be performed by using an X-ray diffraction (XRD) device. In the CHA zeolite, in an X-ray diffraction spectrum by a powder X-ray analysis method, peaks corresponding to a (211) plane, (104) plane and (220) plane of the CHA zeolite appear in vicinities of 2θ=20.7°, 25.1° and 26.1°, respectively. It is defined that crystallinity of the zeolite of the present invention is evaluated by a sum (X-ray integrated intensity ratio) of integrated intensities of the (211) plane, (104) plane and (220) plane of the zeolite with respect to a sum of integrated intensities of a peak corresponding to a (111) plane in a vicinity of 20=38.7° and a peak corresponding to a (200) plane in a vicinity of 2θ=44.9° in an X-ray diffraction spectrum of lithium fluoride.
[0021] It is preferable that the sum (X-ray integrated intensity ratio) of the integrated intensities of the (211) plane, (104) plane and (220) plane of the zeolite with respect to the sum of the integrated intensities of the (111) plane and (200) plane in the X-ray diffraction spectrum of the lithium fluoride be 3.1 or more.
[0022] Zeolite, in which the above-described X-ray integrated intensity ratio is 3.1 or more, has high crystallinity, has a structure less likely to undergo a change due to heat and the like, has high purifying performance for NOx, and is also excellent in heat resistance and durability. A method for obtaining this X-ray integrated intensity ratio is as described above.
[0023] The composition ratio of SiO 2 /Al 2 O 3 of the above-described CHA zeolite means a molar ratio (SAR) of SiO 2 with respect to Al 2 O 3 in the zeolite. Then, though the composition ratio of SiO 2 /Al 2 O 3 of the CHA zeolite according to the present invention is less than 15, the composition ratio is preferably 5 to 14.9, more preferably 10 to 14.9.
[0024] In the CHA zeolite according to the present invention, the composition ratio of SiO 2 /Al 2 O 3 therein is less than 15, and accordingly, acid sites of the CHA zeolite concerned can be ensured by a sufficient number, and the CHA zeolite can exchange ions thereof with metal ions by using the acid sites, and can carry a large amount of Cu, and therefore, is excellent in purifying performance of NOx. When the composition ratio of SiO 2 /Al 2 O 3 in the CHA zeolite exceeds 15, then a carried amount of Cu is small, and a purification rate for NOx is lowered.
[0025] Note that the molar ratio SiO 2 /Al 2 O 3 of the zeolite can be measured by using the fluorescent X-ray analysis (XRF).
[0026] In the zeolite according to the present invention, it is preferable that Cu is carried by 3.5 to 6.0 wt % with respect to the zeolite. Cu is carried by 3.5 to 6.0 wt %, whereby high NOx purifying performance is obtained by means of a small amount of the zeolite. It is more preferable that Cu concerned be contained by 4.0 to 5.5 wt %.
[0027] A Cu ion exchange method can be performed by immersing the zeolite into a type of aqueous solution, which is selected from an aqueous solution of copper acetate, an aqueous solution of copper nitrate, an aqueous solution of copper sulfate and an aqueous solution of copper chloride. Among them, the aqueous solution of copper acetate is preferable. This is because a large amount of Cu can be carried at a time by the aqueous solution of copper acetate. For example, an aqueous solution of copper acetate (II), in which a concentration of copper is 0.1 to 2.5 wt %, is subjected to ion exchange under the atmospheric pressure at a solution temperature ranging from room temperature to 50° C., whereby the copper can be carried on the zeolite.
[0028] The average particle size of the CHA zeolite according to the present invention is preferably 0.1 to 1.0 μm, more preferably 0.1 to 0.5 μm. In a case of producing the honeycomb catalyst by using the zeolite having such a small average particle size, water absorption displacement thereof becomes small.
[0029] The average particle size of the CHA zeolite according to the present invention is 0.1 to 1.0 μm, whereby a pore size of the honeycomb catalyst made of the CHA zeolite becomes an appropriate size, and sufficient purifying performance for NOx can be exerted, and moreover, the water absorption displacement is not increased, and an occurrence of a crack of the honeycomb catalyst can be suppressed.
[0030] The average particle size of the zeolite is obtained from an average value of diagonal lines, which is obtained by photographing an SEM picture by using a scanning electron microscope (SEM; S-4800 made by Hitachi High-Technologies Corporation) and measuring lengths of all diagonal lines of ten particles. Note that, as measuring conditions, an acceleration voltage is set to 1 kV, an emission is set to 10 μA, and a WD is set to 2.2 mm or less. In general, particles of the CHA zeolite are cubic, and become quadrate at a time of being imaged two-dimensionally by a SEM picture. Therefore, the number of diagonal lines in each of the particles is two.
[0031] In the honeycomb catalyst of the present invention, it is preferable that the CHA zeolite be contained by 150 to 350 g/L with respect to the whole of the honeycomb unit. When the content of the CHA zeolite is less than 150 g/L, the purifying performance for NOx is lowered, and when the content exceeds 350 g/L, then the water absorption displacement of the honeycomb unit becomes large, and the crack occurs. It is more preferable that the content concerned be 150 to 250 g/L.
[0032] Next, a description will be made of a method for producing the zeolite according to the present invention. The production method includes several methods, and an example thereof will be described below.
[0033] The production method of the zeolite according to the present invention includes a synthesis step of synthesizing the zeolite by causing a reaction among raw material composition composed of a Si source, an Al source, an alkali source, water and a structure regulating agent, wherein, in the synthesis step, a ratio of a number of moles of water with respect to a total number of moles of Si in the Si source and Al in the Al source (number of moles of H 2 O/total number of moles of Si and Al) is 15 or more.
[0034] In the production method of the zeolite according to the present invention, first, there is prepared the raw material composition composed of the Si source, the Al source, the alkali source, water, and the structure directing agent.
[0035] The Si source refers to a compound, salt and a composition, which serve as raw materials of such a silicon component of the zeolite. As the Si source, for example, there can be used colloidal silica, amorphous silica, sodium silicate, tetraethyl orthosilicate, aluminosilicate gel, and the like, and two or more thereof may be used in combination. Among them, colloidal silica is preferable since the zeolite with a particle size of 0.1 to 0.5 μm can be obtained.
[0036] As the Al source, for example, there are mentioned aluminum sulfate, sodium aluminate, aluminum hydroxide, aluminum chloride, aluminosilicate gel, dried aluminum hydroxide gel and the like. Among them, aluminum hydroxide and dried aluminum hydroxide gel are preferable.
[0037] In order to produce the CHA zeolite taken as a target, it is preferable to use a Si source and an Al source, which have substantially the same molar ratio as a molar ratio (SiO 2 /Al 2 O 3 ) of the zeolite to be produced, and the molar ratio (SiO 2 /Al 2 O 3 ) in the raw material composition is preferably set to 5 to 30, more preferably set to 10 to 15.
[0038] As the alkali source, for example, there can be used sodium hydroxide, potassium hydroxide, rubidium hydroxide, cesium hydroxide, lithium hydroxide, alkaline components in aluminate and silicate, an alkaline component in aluminosilicate gel, and the like, and two or more thereof may be used in combination. Among them, potassium hydroxide, sodium hydroxide and lithium hydroxide are preferable.
[0039] With regard to an amount of water, the ratio of the number of moles of water with respect to the total number of moles of Si in the Si source and Al in the Al source (that is, number of moles of H 2 O/total number of moles of Si and Al) is 15 or more; however, it is more preferable that the ratio of the number of moles of water with respect to the total number of moles of Si in the Si source and Al in the Al source (that is, number of moles of H 2 O/total number of moles of Si and Al) be 17 to 25.
[0040] The structure directing agent (hereinafter, also referred to as SDA) refers to organic molecules which direct a pore diameter and crystal structure of the zeolite. By a type and the like of the structure directing agent, the structure and the like of the zeolite to be obtained can be controlled.
[0041] As the structure directing agent, there can be used at least one selected from the group consisting of: a hydroxide, a halide, a carbonate, a methyl carbonate, a sulfate and a nitrate, each of which uses N,N,N-trialkyladamantane ammonium as a cation; and a hydroxide, a halide, a carbonate, a methyl carbonate, a sulfate and a nitrate, each of which uses, as a cation, an N,N,N-trimethyl-benzyl ammonium ion, N-alkyl-3-quinuclidinol ion, or N,N,N-trialkyl exoamino norbomene. Among them, it is preferable to use at least one selected from the group consisting of N,N,N-trimethyl adamantine ammonium hydroxide (hereinafter, also referred to as TMAAOH), N,N,N-trimethyl adamantane ammonium halide, N,N,N-trimethyl adamantane ammonium carbonate, N,N,N-trimethyl adamantane ammonium methyl carbonate, and N,N,N-trimethyl adamantane ammonium sulfate, and it is more preferable to use TMAAOH.
[0042] In the production method of the zeolite according to the present invention, it is preferable to further add a seed crystal of the zeolite to the raw material composition. By using the seed crystal, a crystallization rate of the zeolite is increased, whereby a time for the production of the zeolite can be shortened, and yield is enhanced.
[0043] As the seed crystal of the zeolite, it is preferable to use such zeolite having the CHA structure.
[0044] It is preferable that an additional amount of the seed crystal of the zeolite be small; however, in consideration of a reaction speed, an effect of suppressing impurities, and the like, the additional amount is preferably 0.1 to 20 wt %, more preferably 0.5 to 15 wt % with respect to an additional amount of such a silica component contained in the raw material composition.
[0045] In the production method of the zeolite according to the present invention, the zeolite is synthesized by causing the reaction of the prepared raw material composition, and it is preferable to synthesize the zeolite by performing hydrothermal synthesis for the raw material composition. Such a method of the hydrothermal synthesis can be performed in a similar way to the production method of the first zeolite.
[0046] In the production method of the zeolite according to the present invention, the zeolite is synthesized by causing the reaction of the prepared raw material composition. Specifically, it is preferable to synthesize the zeolite by performing the hydrothermal synthesis for the raw material composition.
[0047] A reaction vessel for use in the hydrothermal synthesis is not particularly limited as long as the reaction vessel concerned is usable for the known hydrothermal synthesis, and may be a heat-resistant and pressure-resistant vessel such as an autoclave. The raw material composition is charged into the reaction vessel, and the reaction vessel is hermetically sealed and heated, whereby the zeolite can be crystallized.
[0048] In the case of synthesizing the zeolite, it is preferable that a raw material mixture be in a state of being stirred and mixed though a stationary state thereof is allowed.
[0049] A heating temperature in the case of synthesizing the zeolite is preferably 100 to 200° C., more preferably 120 to 180° C. When the heating temperature is less than 100° C., then the crystallization rate becomes slow, and the yield becomes prone to be lowered. Meanwhile, when the heating temperature exceeds 200° C., then impurities are prone to be generated.
[0050] It is preferable that a heating time in the case of synthesizing the zeolite be 10 to 200 hours. When the heating time is less than 10 hours, then unreacted raw materials remain, and the yield becomes prone to be lowered. Meanwhile, even if the heating time exceeds 200 hours, the yield and the crystallinity are not enhanced any more.
[0051] A pressure in the case of synthesizing the zeolite is not particularly limited, and may satisfactorily be a pressure generated when the raw material composition charged into the hermetically sealed vessel is heated to the above-described temperature range; however, the pressure may be increased according to needs by adding inert gas such as nitrogen.
[0052] In the production method of the zeolite according to the present invention, after the zeolite is synthesized, preferably, the zeolite is cooled sufficiently, is subjected to solid-liquid separation, is washed by means of a sufficient amount of water, and is dried. A drying temperature is not particularly limited, and may be an arbitrary temperature within a range of 100 to 150° C.
[0053] The synthesized zeolite contains the SDA in pores, and accordingly, the SDA may be removed according to needs. The SDA can be removed, for example, by liquid phase treatment using an acidic solution or a liquid chemical containing an SDA-decomposing component, exchange treatment using resin, thermal decomposition or the like.
[0054] By the process described above, the zeolite having the CHA structure, in which the composition ratio of SiO 2 /Al 2 O 3 is less than 15, and the average particle size is 0.1 to 0.5 μm, can be produced.
[0055] In the honeycomb catalyst of the present invention, the honeycomb unit may contain zeolite other than the CHA zeolite and silicoaluminophosphate (SAPO) to an extent that these would not impair the effects of the present invention.
[0056] Oxide Having Positive Linear Expansion Coefficient
[0057] In the present invention, as the oxide having the positive linear expansion coefficient (hereinafter, also simply referred to as “oxide”), for example, particles of alumina, titania, zirconia, silica, ceria, magnesium and the like are mentioned. Two or more of these may be used in combination. The inorganic particles are preferably particles of at least one selected from the group consisting of alumina, titania and zirconia, more preferably particles of any one of alumina, titania and zirconia. The oxide having the positive linear expansion coefficient refers to a substance in which a volume expands due to a temperature rise, and by a push-rod dilatometer, the linear expansion coefficient is measured at a temperature rise rate of 10° C./min within 50 to 700° C. with reference to alumina in which a linear expansion coefficient is known.
[0058] The average particle size of the oxide is preferably 0.01 to 5 μm, more preferably 0.02 to 2 μm. If the average particle size of the oxide is 0.01 to 5 μm, then it becomes possible to adjust the pore size of the honeycomb unit.
[0059] Note that the average particle size of the oxide is a particle size (Dv50) corresponding to a 50% integral value in the grain size distribution (in volume base) obtained by a laser diffraction/scattering method.
[0060] In the honeycomb catalyst of the present invention, the ratio (X:Y) of the volume of the zeolite and the volume (Y) of the oxide in the honeycomb unit is 50:50 to 90:10, preferably 60:40 to 85:15. If the volume ratio of the zeolite is less than 50 (if the volume ratio of the oxide exceeds 50), then the purifying performance for NOx is lowered, and if the volume ratio of the zeolite exceeds 90 (if the volume ratio of the oxide is less than 10), then an effect of lowering an absolute value of the linear expansion coefficient of the honeycomb unit is not obtained, and the honeycomb unit becomes prone to be broken owing to a thermal stress.
[0061] In the honeycomb catalyst of the present invention, a ratio (B/A) of the average particle size (A) of the zeolite and the average particle size (B) of the oxide is preferably 1/10 to 5. If a value of the ratio concerned is 1/10 to 5, then gaps between portions of the zeolite are not filled with the oxide, and the purifying performance for NOx can be prevented from being lowered. Moreover, the particles can be brought into appropriate contact with one another, sufficient strength is obtained, and the occurrence of the crack can be prevented.
[0062] Other Inorganic Particles
[0063] The honeycomb catalyst of the present invention may contain inorganic particles other than the zeolite and the oxide to an extent that these would not impair the effects of the present invention. As such inorganic particles, particles of silicon carbide, silicon nitride, aluminum titanate and the like are mentioned.
[0064] Inorganic Binder
[0065] In the honeycomb catalyst of the present invention, the inorganic binder contained in the honeycomb unit is not particularly limited. However, from a viewpoint of maintaining strength as the honeycomb catalyst, preferable examples of the inorganic binder include solid contents contained in alumina sol, silica sol, titania sol, water glass, sepiolite, attapulgite, and boehmite, and two or more thereof may be used in combination.
[0066] A content of the inorganic binder in the honeycomb unit is preferably 3 to 20 vol %, more preferably 5 to 15 vol %. If the content of the inorganic binder is 3 to 20 vol %, then excellent NOx purifying performance can be maintained without causing a decrease of the strength of the honeycomb unit.
[0067] Inorganic Fiber
[0068] In the honeycomb catalyst of the present invention, it is preferable that the honeycomb unit further contain inorganic fiber in order to enhance the strength thereof.
[0069] It is preferable that the inorganic fiber contained in the honeycomb unit be made at least one selected from the group consisting of alumina, silica, silicon carbide, silica alumina, glass, potassium titanate and aluminum borate. This is because all of these materials have high heat resistance, are free from erosion even at a time of being used as catalyst carriers in the SCR system, and can maintain the effect as reinforcement materials.
[0070] A content of the inorganic fiber in the honeycomb unit is preferably 3 to 30 vol %, more preferably 5 to 20 vol %. If the above-described content is 3 to 30 vol %, then a content of the zeolite in the honeycomb unit is ensured sufficiently while enhancing the strength of the honeycomb unit, and the purifying performance for NOx can be prevented from being lowered.
[0071] Honeycomb Catalyst
[0072] The honeycomb catalyst of the present invention is a honeycomb catalyst including a honeycomb unit that is composed of the above-described components and has a plurality of through holes provided in parallel in a longitudinal direction while being separated from one another by partition walls.
[0073] FIG. 1 shows an example of the honeycomb catalyst of the present invention. A honeycomb catalyst 10 shown in FIG. 1 includes a single honeycomb unit 11 in which a plurality of through holes 11 a are provided in parallel in the longitudinal direction while being separated from one another by partition walls 11 b , wherein an outer circumference coating layer 12 is formed on an outer circumferential surface of the honeycomb unit 11 . Moreover, the honeycomb unit 11 contains the zeolite and the inorganic binder.
[0074] In the honeycomb catalyst of the present invention, a maximum peak pore size of the partition walls of the honeycomb unit (hereinafter, sometimes referred to as a maximum peak pore size of the honeycomb unit) is preferably 0.03 to 0.20 μm, more preferably 0.05 to 0.15 μm.
[0075] Note that the pore size of the honeycomb unit can be measured by a mercury press—in method. The pore size is measured within a range of 0.01 to 100 μm while setting a contact angle of mercury at this time to 130° and setting surface tension thereof to 485 mN/m. A value of the pore size at a time when the pore size reaches a maximum peak within this range is referred to as the maximum peak pore size.
[0076] In the honeycomb catalyst of the present invention, it is preferable that a porositiy of the honeycomb unit be 40 to 70%. If the porosity of the honeycomb unit is less than 40%, then exhaust gas becomes less likely to enter insides of the partition walls of the honeycomb unit, and the zeolite is not used effectively for purifying NOx. Meanwhile, if the porosity of the honeycomb unit exceeds 70%, then the strength of the honeycomb unit becomes insufficient.
[0077] Note that the porosity of the honeycomb unit can be measured by a gravimetric method. A measuring method of the porosity by the gravimetric method is as follows.
[0078] The honeycomb unit is cut into a size of 7 cells×7 cells×10 mm to prepare a measurement sample, and this sample is subjected to ultrasonic cleaning by using ion exchange water and acetone, followed by drying at 100° C. in an oven. Subsequently, by using a measuring microscope (Measuring Microscope MM-40 made by Nikon Corporation; magnification: 100 power), dimensions of a cross-sectional shape of the sample are measured, and a volume thereof is obtained from a geometrical calculation. Note that, in a case where the volume cannot be obtained from the geometrical calculation, the volume is calculated by image processing for a picture of such a cross section.
[0079] Thereafter, a weight of the sample in a case where it is assumed that the sample is a perfect dense body is calculated based on the calculated volume and a real density of the sample, which is measured by a pycnometer.
[0080] Note that a measurement procedure by the pycnometer is set as follows. The honeycomb unit is crushed to prepare powder of 23.6 cc, and the obtained powder is dried at 200° C. for 8 hours. Thereafter, by using Auto Pycnometer 1320 (made by Micrometrics Instrument Corporation), the real density is measured in conformity with JIS-R-1620 (1995). Note that an evacuation time at this time is set to 40 min.
[0081] Next, an actual weight of the sample is measured by an electronic balance (HR202i made by Shimadzu Corporation), and the porosity is calculated by a following expression.
[0000] 100−(actual weight/weight as dense body)×100(%)
[0082] In the honeycomb catalyst of the present invention, it is preferable that an aperture ratio of a cross section perpendicular to the longitudinal direction of the honeycomb unit be 50 to 75%. If the aperture ratio of the cross section perpendicular to the longitudinal direction of the honeycomb unit is less than 50%, then the zeolite is not used effectively for purifying NOx. Meanwhile, if the aperture ratio of the cross section perpendicular to the longitudinal direction of the honeycomb unit exceeds 75%, then the strength of the honeycomb unit becomes insufficient.
[0083] In the honeycomb catalyst of the present invention, it is preferable that a density of the through holes on the cross section perpendicular to the longitudinal direction of the honeycomb unit be 62 to 186 pcs/cm 2 . If the density of the through holes concerned is 62 to 186 pcs/cm 2 , then the zeolite and the exhaust gas contact each other with ease, and the purifying performance for NOx can be exerted sufficiently, and in addition, an increase of a pressure loss of the honeycomb catalyst can be suppressed.
[0084] In the honeycomb catalyst of the present invention, a thickness of the partition walls of the honeycomb unit is preferably 0.1 to 0.3 mm, more preferably 0.1 to 0.25 mm. If the thickness of the partition walls of the honeycomb unit is 0.1 to 0.3 mm, then a sufficient strength is obtained, and in addition, the exhaust gas enters the inside of each of the partition walls of the honeycomb unit with ease, and the zeolite is used effectively for purifying NOx.
[0085] In the honeycomb catalyst of the present invention, in a case where the outer circumference coating layer is formed in the honeycomb unit, it is preferable that a thickness of the outer circumference coating layer be 0.1 to 5.0 mm. If the thickness of the outer circumference coating layer is less than 0.1 mm, then the effect of enhancing the strength of the honeycomb catalyst becomes insufficient. Meanwhile, if the thickness of the outer circumference coating layer exceeds 5.0 mm, then the content of the zeolite per unit volume of the honeycomb catalyst is lowered, and the purifying performance for NOx is lowered.
[0086] A shape of the honeycomb catalyst of the present invention is not limited to such a columnar shape, and may be prism-like, elliptic cylinder-like, chamfered prism-like (for example, chamfered triangular prism-like), and so on.
[0087] Note that, in a case where the honeycomb catalyst of the present invention has such a columnar shape, a diameter thereof is preferably 140 to 350 mm, and a length thereof is preferably 75 to 310 mm.
[0088] In the honeycomb catalyst of the present invention, a shape of the through holes is not limited to a quadrangular prism shape, and may be triangular prism-like, hexagonal prism-like, and so on.
[0089] The above-described honeycomb catalyst of the present invention can be manufactured, for example, in the following manner. First, a raw material paste, which contains the zeolite and the inorganic binder, and according to needs, further contains the inorganic fiber and the inorganic particles, is used and subjected to extrusion molding, and a columnar honeycomb compact is fabricated, in which a plurality of through holes are provided in parallel in the longitudinal direction while being separated from one another by partition walls.
[0090] The inorganic binder contained in the raw material paste is as already mentioned, and an organic binder, a dispersion medium, a molding auxiliary and the like may be added to the raw material paste appropriately according to needs.
[0091] The organic binder is not particularly limited; however, examples thereof include methyl cellulose, carboxy methyl cellulose, hydroxyethyl cellulose, polyethylene glycol, phenolic resin, and epoxy resin, and two or more thereof may be used in combination. Note that an additional amount of the organic binder is preferably 1 to 10% with respect to a total weight of the zeolite, the inorganic particles, the inorganic binder and the inorganic fiber.
[0092] The dispersion medium is not particularly limited; however, examples thereof include water, an organic solvent such as benzene, and alcohol such as methanol, and two or more thereof may be used in combination.
[0093] The molding auxiliary is not particularly limited; however, examples thereof include ethylene glycol, dextrin, fatty acid, fatty acid soap, and polyalcohol, and two or more thereof may be used in combination.
[0094] Moreover, a pore-forming material may be added to the raw material paste according to needs. The pore-forming material is not particularly limited; however, examples thereof include polystyrene particles, acrylic particles, and starch, and two or more thereof may be used in combination. Among them, the polystyrene particles are preferable.
[0095] The particle sizes of the CHA zeolite and the pore-forming material are controlled, whereby a pore size distribution of the partition walls can be controlled within a predetermined range.
[0096] Moreover, even in a case where the pore-forming material is not added, the particle size of the inorganic particles is controlled, whereby the pore size distribution of the partition walls can be controlled within the predetermined range.
[0097] When the raw material paste is prepared, it is desirable that the raw material paste be mixed and kneaded, or the raw material paste may be mixed by using a mixer, an attritor or the like, or the raw material paste may be kneaded by using a kneader and the like.
[0098] Next, the honeycomb compact is dried by using a dryer such as a microwave dryer, a hot air dryer, a dielectric dryer, a decompression dryer, a vacuum dryer, and a freeze dryer, whereby a honeycomb dried body is prepared.
[0099] Moreover, the honeycomb dried body is degreased to prepare a honeycomb degreased body. A degreasing condition can be selected appropriately in accordance with a type and amount of such organic matter contained in the honeycomb dried body; however, is preferably 200° C. to 500° C. for 2 to 6 hours.
[0100] Next, the honeycomb degreased body is fired, whereby a columnar honeycomb unit is fabricated. A firing temperature is preferably 600 to 1000° C., more preferably 600 to 800° C. If the firing temperature is 600 to 1000° C., then reaction sites of the zeolite are not reduced, and the honeycomb unit having a sufficient strength is obtained.
[0101] Next, an outer circumference coating layer paste is applied to the outer circumferential surface of the columnar honeycomb unit except for both end surfaces thereof. The outer circumference coating layer paste is not particularly limited; however, examples thereof include a mixture of an inorganic binder and inorganic particles, a mixture of an inorganic binder and inorganic particles, a mixture of the inorganic binder and inorganic fiber, and a mixture of the inorganic binder, the inorganic particles and the inorganic fiber.
[0102] The inorganic binder contained in the outer circumference coating layer paste is not particularly limited; however, is added as silica sol, alumina sol or the like, and two or more thereof may be used in combination. In particular, the inorganic binder is preferably added as silica sol.
[0103] The inorganic particles contained in the outer circumference coating layer paste is not particularly limited; however, examples thereof include: oxide particles made of zeolite, eucryptite, alumina, silica, or the like; carbide particles made of silicon carbide or the like; and nitride particles made of silicon nitride, boron nitride, or the like, and two or more thereof may be used in combination. Among them, the particles made of eucryptite, which has a linear expansion coefficient approximate to that of the honeycomb unit, are preferable.
[0104] The inorganic fiber contained in the outer circumference coating layer paste is not particularly limited; however, examples thereof include silica alumina fiber, mullite fiber, alumina fiber, silica fiber, and glass fiber, and two or more thereof may be used in combination. Among them, the glass fiber is preferable.
[0105] The outer circumference coating layer paste may further contain an organic binder.
[0106] The organic binder contained in the outer circumference coating layer paste is not particularly limited; however, examples thereof include polyvinyl alcohol, methyl cellulose, ethyl cellulose, and carboxy methyl cellulose, and two or more thereof may be used in combination.
[0107] The outer circumference coating layer paste may further contain balloons which are fine hollow spheres of oxide-based ceramics, the pore-forming material, and the like.
[0108] The balloons contained in the outer circumference coating layer paste are not particularly limited; however examples thereof include alumina balloons, glass microballoons, sirasu balloons, fly ash balloons, and mullite balloons, and two or more thereof may be used in combination. Among them, the alumina balloons are preferable.
[0109] The pore-forming material contained in the outer circumference coating layer paste is not particularly limited; however, examples thereof include spherical acrylic particles and graphite, and two or more thereof may be used in combination.
[0110] Next, the honeycomb unit 11 , to which the outer circumference coating layer paste is applied, is dried and solidified, whereby the columnar honeycomb catalyst is fabricated. At this time, in a case where the organic binder is contained in the outer circumference coating layer paste, it is preferable to degrease the honeycomb unit 11 . The degreasing condition can be selected appropriately in accordance with the type and amount of the organic matter; however, is preferably 200° C. to 500° C. for 1 hour.
[0111] FIG. 2 shows another example of the honeycomb catalyst of the present invention. A honeycomb catalyst 10 ′ shown in FIG. 2 has the same configuration as that of the honeycomb catalyst 10 except that a plurality of honeycomb units 11 ′ (refer to FIG. 3 ), in which a plurality of through holes 11 a are provided in parallel in the longitudinal direction while being separated from one another by partition walls 11 b , are adhered to one another via an adhesive layer 13 .
[0112] It is preferable that a cross-sectional area of a cross section perpendicular to the longitudinal direction in the honeycomb unit 11 ′ be 10 to 200 cm 2 . If the above-described cross-sectional area is less than 10 cm 2 , then a pressure loss of the honeycomb catalyst 10 ′ is increased. Meanwhile, if the above-described cross-sectional area exceeds 200 cm 2 , then it is difficult to adhere the honeycomb units 11 ′ to one another.
[0113] The honeycomb unit 11 ′ has the same configuration as that of the honeycomb unit 11 except for the cross-sectional area of the cross section perpendicular to the longitudinal direction.
[0114] It is preferable that a thickness of the adhesive layer 13 be 0.1 to 3.0 mm. If the thickness of the adhesive layer 13 is less than 0.1 mm, then adhesion strength of the honeycomb unit 11 ′ becomes insufficient. Meanwhile, if the thickness of the adhesive layer 13 exceeds 3.0 mm, then the pressure loss of the honeycomb catalyst 10 ′ is increased, and a crack occurs in the adhesive layer.
[0115] Next, a description is made of an example of a manufacturing method of the honeycomb catalyst 10 ′ shown in FIG. 2 . First, the sectorial prism-like honeycomb units 11 ′ are fabricated in a similar way to the honeycomb unit 11 that composes the honeycomb catalyst 10 . Next, an adhesive layer paste is applied to outer peripheral surfaces of the honeycomb units 11 ′ except for circular arc surfaces thereof, and the honeycomb units 11 ′ are adhered to one another, and are then dried and solidified, whereby an aggregate of the honeycomb units 11 ′ is fabricated.
[0116] The adhesive layer paste is not particularly limited; however, examples thereof include a mixture of an inorganic binder and inorganic particles, a mixture of an inorganic binder and inorganic particles, a mixture of the inorganic binder and inorganic fiber, and a mixture of the inorganic binder, the inorganic particles and the inorganic fiber.
[0117] The inorganic binder contained in the adhesive layer paste is not particularly limited; however, is added as silica sol, alumina sol or the like, and two or more thereof may be used in combination. In particular, the inorganic binder is preferably added as silica sol.
[0118] The inorganic particles contained in the adhesive layer paste is not particularly limited; however, examples thereof include: oxide particles made of zeolite, eucryptite, alumina, silica, or the like; carbide particles made of silicon carbide or the like; and nitride particles made of silicon nitride, boron nitride, or the like, and two or more thereof may be used in combination. Among them, the particles made of eucryptite, which has a linear expansion coefficient approximate to that of the honeycomb unit, are preferable.
[0119] The inorganic fiber contained in the adhesive layer paste is not particularly limited; however, examples thereof include silica alumina fiber, mullite fiber, alumina fiber, and silica fiber, and two or more thereof may be used in combination. Among them, the alumina fiber is preferable.
[0120] Moreover, the adhesive layer paste may contain an organic binder.
[0121] The organic binder contained in the adhesive layer paste is not particularly limited; however, examples thereof include polyvinyl alcohol, methyl cellulose, ethyl cellulose, and carboxy methyl cellulose, and two or more thereof may be used in combination.
[0122] The adhesive layer paste may further contain balloons which are fine hollow spheres of oxide-based ceramics, a pore-forming material, and the like.
[0123] The balloons contained in the adhesive layer paste are not particularly limited; however examples thereof include alumina balloons, glass microballoons, sirasu balloons, fly ash balloons, and mullite balloons, and two or more thereof may be used in combination. Among them, the alumina balloons are preferable.
[0124] The pore-forming material contained in the adhesive layer paste is not particularly limited; however, examples thereof include spherical acrylic particles and graphite, and two or more thereof may be used in combination.
[0125] Next, the aggregate of the honeycomb unit 11 ′ is cut and ground according to needs in order to enhance circularity thereof, and a columnar aggregate of the honeycomb units 11 ′ is fabricated.
[0126] Next, an outer circumference coating layer paste is applied to the outer circumferential surface of the columnar aggregate of the honeycomb units 11 ′ except for both end surfaces thereof.
[0127] The outer circumference coating layer paste may be the same as or different from the adhesive layer paste.
[0128] Next, the columnar aggregate of the honeycomb units 11 ′, to which the outer circumference coating layer paste is applied, is dried and solidified, whereby the columnar honeycomb catalyst 10 ′ is fabricated. At this time, in a case where the organic binder is contained in the adhesive layer paste and/or the outer circumference coating layer paste, it is preferable to degrease the honeycomb units 11 ′. The degreasing condition can be selected appropriately in accordance with the type and amount of the organic matter; however, is preferably 500° C. for 1 hour.
[0129] The honeycomb catalyst 10 ′ is composed in such a manner that the four honeycomb units 11 ′ are adhered to one another via the adhesive layer 13 ; however, the number of honeycomb units which compose the honeycomb catalyst is not particularly limited. For example, such a columnar honeycomb catalyst may be composed in such a manner that 16 pieces of quadrangular prism-like honeycomb units are adhered to one another via the adhesion layer.
[0130] Note that the outer circumference coating layers 12 do not have to be formed in the honeycomb catalysts 10 and 10 ′.
EXAMPLES
[0131] Hereinafter, a more specific description will be made of the present invention by examples; however, the present invention is not limited to the following examples.
Example 1
Fabrication of Honeycomb Catalyst
[0132] 22.7 wt % of CHA zeolite shown in Table 1, 20.2 wt % of titanium oxide with an average particle size of 0.2 μm, 6.8 wt % of pseudo-boehmite as an inorganic binder, 6.8 wt % of glass fiber with an average fiber length of 100 μm, 6.2 wt % of methyl cellulose, 3.4 wt % of a surfactant, 4.8 wt % of polystyrene particles with an average particle size of 0.8 μm, which serve as a pore-forming material, and 29.2 wt % of ion exchange water were mixed and kneaded together, whereby a raw material paste was prepared. Note that, as the zeolite, one in which ions were exchanged with copper ions was used.
[0000]
TABLE 1
COMPAR-
COMPAR-
ATIVE
ATIVE
EXAMPLE
1
2
3
4
5
6
1
2
ZEOLITE
COMPOSITION
13
13
13
13
13
13
13
30
RATIO
(SIO 2 /AL 2 O 3 )
CARRIED
4.2
—
—
4.5
—
3.0
—
3.3
AMOUNT OF
Cu (WT %)
AVERAGE
0.3
0.3
0.3
0.47
0.3
1.34
0.3
0.1
PARTICLE
SIZE (μm)
CONTENT WITH
220
142
240
245
265
222
286
195
RESPECT TO
HONEYCOMB UNIT
OXIDE
COMPOUND NAME
TiO 2
TiO 2
TiO 2
ZrO 2
Al 2 O 3
ZrO 2
—
TiO 2
AVERAGE
0.2
0.2
0.2
0.04
2.6
0.04
—
0.2
PARTICLE
SIZE (μm)
VOLUME RATIO OF THE
7:3
5:5
9:1
7:3
8:2
7:3
10:0
7:3
ZEOLITE AND THE OXIDE
LINEAR EXPANSION
−2
−0.2
−4
−2
−2.6
−2
−4.2
−1
COEFFICIENT
EVALUATION
NO x PURIFYING
200° C.
75
—
—
77
—
69
—
57
PERFORMANCE
525° C.
82
—
—
76
76
—
63
WATER ABSORPTION
0.2
0.13
0.24
0.21
0.2
0.26
0.28
0.18
DISPLACEMENT (%)
[0133] Next, the raw material paste is subjected to extrusion molding by using an extruder, whereby a honeycomb compact was fabricated. Then, by using a reduced-pressure microwave dryer, the honeycomb compact was dried with an output of 4.5 kW at a reduced pressure of 6.7 kPa for 7 minutes, and thereafter, was degreased and fired at an oxygen concentration of 1% at 700° C. for 5 hours, whereby a honeycomb catalyst (honeycomb unit) was fabricated. The honeycomb unit had a square prism shape with a side of 35 mm and a length of 150 mm, in which a density of through holes was 124 pcs/cm 2 , and a thickness of partition walls was 0.20 mm.
Example 2
[0134] 18.0 wt % of CHA zeolite shown in Table 1, 32.8 wt % of titanium oxide with an average particle size of 0.2 μm, 6.6 wt % of pseudo-boehmite as an inorganic binder, 6.6 wt % of glass fiber with an average fiber length of 100 μm, 5.5 wt % of methyl cellulose, 3.0 wt % of a surfactant, 3.8 wt % of polystyrene particles with an average particle size of 0.8 μm, which serve as a pore-forming material, and 23.8 wt % of ion exchange water were mixed and kneaded together, whereby a raw material paste was prepared. Note that, as the zeolite, one in which ions were not exchanged with copper ions was used. Subsequently, by using the prepared raw material paste, a honeycomb catalyst of Example 2 was fabricated in a similar way to Example 1.
Example 3
[0135] 31.2 wt % of CHA zeolite shown in Table 1, 6.3 wt % of titanium oxide with an average particle size of 0.2 μm, 6.4 wt % of pseudo-boehmite as an inorganic binder, 6.4 wt % of glass fiber with an average fiber length of 100 urn, 6.7 wt % of methyl cellulose, 3.7 wt % of a surfactant, 6.6 wt % of polystyrene particles with an average particle size of 0.8 μm, which serve as a pore-forming material, and 32.7 wt % of ion exchange water were mixed and kneaded together, whereby a raw material paste was prepared. Note that, as the zeolite, one in which ions were not exchanged with copper ions was used. Subsequently, by using the prepared raw material paste, a honeycomb catalyst of Example 3 was fabricated in a similar way to Example 1.
Example 4
[0136] 22.2 wt % of CHA zeolite shown in Table 1, 24.8 wt % of zirconia with an average particle size of 0.04 μm, 5.8 wt % of pseudo-boehmite as an inorganic binder, 5.8 wt % of glass fiber with an average fiber length of 100 μm, 6.2 wt % of methyl cellulose, 3.4 wt % of a surfactant, and 31.7 wt % of ion exchange water were mixed and kneaded together, whereby a raw material paste was prepared. Note that, as the zeolite, one in which ions were exchanged with copper ions was used. Subsequently, by using the prepared raw material paste, a honeycomb catalyst of Example 4 was fabricated in a similar way to Example 1.
Example 5
[0137] 28.3 wt % of CHA zeolite shown in Table 1, 12.2 wt % of alumina with an average particle size of 2.6 μm, 6.5 wt % of pseudo-boehmite as an inorganic binder, 6.5 wt % of glass fiber with an average fiber length of 100 μm, 6.4 wt % of methyl cellulose, 3.5 wt % of a surfactant, 5.9 wt % of polystyrene particles with an average particle size of 0.8 μm, which serve as a pore-forming material, and 30.5 wt % of ion exchange water were mixed and kneaded together, whereby a raw material paste was prepared. Note that, as the zeolite, one in which ions were exchanged with copper ions was used. Subsequently, by using the prepared raw material paste, a honeycomb catalyst of Example 5 was fabricated in a similar way to Example 1.
Example 6
[0138] 22.2 wt % of CHA zeolite shown in Table 1, 24.8 wt % of zirconia with an average particle size of 0.04 μm, 5.8 wt % of pseudo-boehmite as an inorganic binder, 5.8 wt % of glass fiber with an average fiber length of 100 μm, 6.2 wt % of methyl cellulose, 3.4 wt % of a surfactant, and 31.7 wt % of ion exchange water were mixed and kneaded together, whereby a raw material paste was prepared. Note that, as the zeolite, one in which ions were exchanged with copper ions was used. Subsequently, by using the prepared raw material paste, a honeycomb catalyst of Example 6 was fabricated in a similar way to Example 1.
Comparative Example 1
[0139] 40.0 wt % of CHA zeolite shown in Table 1, 7.4 wt % of pseudo-boehmite as an inorganic binder, 7.3 wt % of glass fiber with an average fiber length of 100 μm, 6.7 wt % of methyl cellulose, 3.6 wt % of a surfactant, and 35.0 wt % of ion exchange water were mixed and kneaded together, whereby a raw material paste was prepared. Subsequently, by using the prepared raw material paste, a honeycomb catalyst of Example 5 was fabricated in a similar way to Example 1.
Comparative Example 2
[0140] 25.4 wt % of CHA zeolite shown in Table 1, 19.9 wt % of titanium oxide with an average particle size of 0.2 μm, 6.7 wt % of pseudo-boehmite as an inorganic binder, 6.7 wt % of glass fiber with an average fiber length of 100 μm, 6.0 wt % of methyl cellulose, 3.3 wt % of a surfactant, 5.3 wt % of polystyrene particles with an average particle size of 0.8 μm, which serve as a pore-forming material, and 26.7 wt % of ion exchange water were mixed and kneaded together, whereby a raw material paste was prepared. Note that, as the zeolite, one in which ions were not exchanged with copper ions was used. Subsequently, by using the prepared raw material paste, a honeycomb catalyst of Comparative example 2 was fabricated in a similar way to Example 1.
[0141] Measurement of Linear Expansion Coefficient of Honeycomb Unit
[0142] By a following method, the linear expansion coefficients (coefficients of thermal expansion: CTE) of the honeycomb units fabricated in Examples 1 to 6 and Comparative examples 1 to 5 were measured.
[0143] First, by using a diamond cutter, from each of the honeycomb units, a measurement sample with dimensions of 5 mm×5 mm×25 mm was cut out. Thereafter, the measurement sample was dried at 200° C. for 2 hours, a weight thereof was measured, and the measurement sample was left standing in a steam atmosphere until a water absorption rate thereof reached 10%.
[0144] Next, the measurement sample and an alumina-made reference sample (5 mm×5 mm×25 mm) were installed in line in a hermetically sealed vessel so that longitudinal directions of both thereof could be the horizontal direction. Note that, on these samples, detection bars therefor were installed so as to be brought into contact with center portions of upper surfaces (that is, upper regions with dimensions of 5 mm×25 mm).
[0145] Next, under an argon atmosphere, the measurement sample and the reference sample were held at room temperature to 50° C. for 10 hours, thereafter, were heated up to 700° C. at a temperature rise rate 10° C./min., and were cooled down to room temperature at a rate of 10° C./min. Note that the measurement was performed under an atmosphere where a flow rate of He was 100 ml/min. At this time, the measurement sample and the reference sample expanded thermally, and moreover, the measurement sample was subjected to the water absorption displacement, and a variation in this case was detected by the detection bar. Hence, a linear expansion coefficient of the measurement sample (honeycomb unit) was obtained from a difference between such variations of the reference sample and the measurement sample.
[0146] For the measurement, a thermal expansion coefficient measuring device (NETZSCH DIL402C made by BRUKER Corporation) was used.
[0147] Measurement of Purification Rate for NOX
[0148] By using a diamond cutter, from each of the honeycomb units, a columnar test specimen with a diameter of 25.4 mm and a length of 38.1 mm was cut out. This test specimen was subjected to heat treatment under conditions where a temperature was 650° C., a time was 75 hours, gas was composed of 10% of water, 21% of oxygen and a balance of nitrogen, and a gas flow rate was 1 L/min. Through the test specimen, imitation gas at 200° C. was flown at a space velocity (SV) of 100000/hr, and meanwhile, an amount of NOx flowing out of the test specimen was measured by using a catalyst evaluation device (SIGU-2000/MEXA-6000FT made by HORIBA Ltd.), and the purification rate for NOx, which is represented by the following formula (1), was calculated:
[0000] (Flow-in amount of NOx)−(Flow-out amount of NOx)/(Flow-in amount of NOx)×100 (1)
[0000] Note that, with regard to constituents, the imitation gas contained 262.5 ppm of nitrogen monoxide, 87.5 ppm of nitrogen dioxide, 350 ppm of ammonia, 10% of oxygen, 5% of carbon dioxide, 5% of water, and nitrogen (balance).
[0149] In a similar way, the purification rate [%] for NOx was calculated while flowing the imitation gas at 525° at SV of 150000/hr. With regard to constituents at this time, the imitation gas contained 315 ppm of nitrogen monoxide, 35 ppm of nitrogen dioxide, 385 ppm of ammonia, 10% of oxygen, 5% of carbon dioxide, 5% of water, and nitrogen (balance). Table 1 shows the NOx purification rate of the honeycomb catalysts which used the zeolites obtained in Examples 1 to 6 and Comparative examples 1 and 2.
[0150] Measurement of Water Absorption Displacement
[0151] By using a diamond cutter, from each of the honeycomb units, a square prism-like test specimen with a side of 35 mm and a length of 10 mm was cut out. This test specimen was dried at 200° C. for 2 hours in a dryer. Thereafter, by using a measuring microscope (Measuring Microscope MM-40 made by Nikon Corporation; magnification: 100 power), a distance between absolutely dried outermost walls (distance between an outermost wall on the honeycomb of the test specimen and an opposite outermost wall thereon) was measured. A measurement position was set to a center portion in the longitudinal direction of an outer periphery of the test specimen, and the measurement was performed for only one side of the test specimen. Subsequently, the test specimen was immersed into water for one hour, and water on a surface of such a sample was removed by air blowing, and thereafter, a distance between the water-absorbing outermost walls was measured by a similar measurement method. The water absorption displacement was calculated by Expression (2):
[0000] (Distance between absolutely dried outermost walls−Distance between water-absorbing outermost walls)/(Distance between absolutely dried outermost walls)×100 (1)
[0000] Table 1 shows the water absorption displacements of the honeycomb catalysts which used the zeolites obtained in Examples 1 to 6 and Comparative examples 1 and 2.
[0152] With reference to Table 1, in the honeycomb catalysts of Examples 1 to 5, the linear expansion coefficients were in a range within ±4×10 −6 , there is no apprehension that the crack may occur at the time of usage, and good results were obtained in both of the purification rate for NOx and the water absorption displacement. In contrast, in the honeycomb catalyst of Comparative example 1, the linear expansion coefficient was as high as 4.2×10 −6 . Moreover, the purifying performance for NOx in the honeycomb catalyst of Comparative example 2 was low.
DESCRIPTION OF REFERENCE NUMERALS
[0000]
10 , 10 ′ honeycomb catalyst
11 , 11 ′ honeycomb unit
11 a through hole
11 b partition wall
12 outer circumference coating layer
13 adhesive layer | Provided is a honeycomb catalyst in which a plurality of through holes are provided in proximity to each other in a row arrangement in the lengthwise direction, and are set apart by partitions. A honeycomb unit contains at least two types of inorganic particles and an inorganic binder. The inorganic particles contain zeolite having an SiO2/Al2O3 composition ratio of less than 15 and a CHA structure and an oxide other than zeolite, which has a positive thermal expansion coefficient. The ratio (X:Y) of the volume (X) of zeolite and the volume (Y) of oxide is 50:50 to 80:20. A displacement amount of absorbed water is reduced and cracking is controlled while maintaining high NOx purging performance. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a stainless steel sheet with excellent thermal fatigue properties, and to an automotive exhaust-gas path member using the same, and in particular, to a member that constitutes the upstream part of the exhaust-gas path and is heated to temperatures of 700° C. or higher upon the use of automobiles.
[0003] 2. Description of the Related Art
[0004] Among automotive exhaust-gas path members, an upstream member, which is heated to 700° C. or higher during use thereof, is required to have, first of all, heat resistance in a range of high temperatures exceeding 700° C. In this regard, with the main goal of increasing high-temperature strength in the high-temperature range of 700˜1000° C., characteristic materials therefor have been developed. Further, the automotive exhaust-gas path member undergoes repeated heat cycles, including heating to the high-temperature range and cooling to room temperature, in response to the starting and stopping of an engine. Accordingly, strength in an intermediate temperature range of 500˜700° C. between the heating process and the cooling process is also regarded as important, and thus, component designs for increasing high-temperature strength in a wide temperature range from 500° C. to 1000° C. are under study.
[0005] Because it is important that the automotive exhaust-gas path member be imparted with excellent thermal fatigue properties for resistance to repeated heating and cooling, Japanese Patent No. 3468156 discloses ferritic stainless steel, which is intended to prevent the strength thereof from decreasing in an intermediate temperature range of 600˜750° C. because the thermal fatigue properties may be increased depending on an increase in the strength in the intermediate temperature range. To this end, 1˜3% of Cu is contained in steel, thus producing a fine precipitate of Cu in the intermediate temperature range.
[0006] In addition, WO 03/004714 discloses ferritic stainless steel containing 1.0˜1.7% Cu to precipitate Cu during heating so as to increase high-temperature strength at 700° C. or 800° C.
SUMMARY OF THE INVENTION
Problems to be Solved by the Invention
[0007] As mentioned above, however, to increase the high-temperature strength in the wide temperature range from 500° C. to 1000° C. merely depends on component designs in which specific elements are added in large amounts, undesirably resulting in increased material costs. Moreover, forming workability is poor.
[0008] In Japanese Patent No. 3468156 and WO 03/004714, the strength of the steel sheet at 600° C. or in the temperature range of 700˜800° C. is increased using precipitation strengthening by the Cu precipitate through the addition of Cu.
[0009] However, the present inventors have conducted intensive investigation and thus discovered that, even if ferritic stainless steel simply containing a predetermined amount of Cu is annealed, thermal fatigue properties necessary for the upstream member of the automotive exhaust-gas path, which undergoes repeated heating to temperatures exceeding 700° C. and cooling to room temperature, may not always be repeatedly exhibited.
[0010] The present invention aims to provide a ferritic stainless steel sheet for use in the upstream member of an automotive exhaust-gas path, through the development of a technique for stably improving thermal fatigue properties, having a strong correlation with the durability of the member, using relatively inexpensive component designs while fundamentally imparting high-temperature strength, forming workability, and low-temperature toughness.
Means for Solving the Problems
[0011] As a result of further investigation by the present inventors, to increase the durability and reliability of the upstream member of the automotive exhaust-gas path, a stable improvement in thermal fatigue properties has been found to be very favorable, after taking everything into consideration. Fundamental durability high-temperature strength and oxidation resistance) of the high-temperature range exceeding 700° C. reaches a considerably high level at present, due to technical advancement of the prior art. More enhancements in such properties need the addition of specific elements and so on, leading to high costs. Further, durability (thermal fatigue properties), which allows the automobiles to endure heat cycles of heating and cooling upon the use thereof, should be greatly improved. In the current situation, it is considered that the improvement of this durability is very effective in increasing the durability and reliability of the upstream member of the automotive exhaust-gas path.
[0012] Leading to the present invention, intensive and thorough research into a ferritic stainless steel sheet containing Cu, carried out by the present inventors, resulted in the finding that the form of the Cu precipitate (here, referred to as “ε-Cu phase”) is controlled to exist in any predetermined state in the step before the steel sheet is applied to actual use as the exhaust-gas member, and thereby thermal fatigue properties may be stably improved under repeated cycles of subsequent heating and cooling.
[0013] According to the present invention, the ferritic stainless steel sheet (e.g., steel plate) with excellent thermal fatigue properties includes, by mass %, 0.03% or less of C, 1.0% or less of Si, 1.5% or less of Mn, 0.6% or less of Ni, 10˜20% of Cr, 0.05˜0.30% of Ti, 0.51˜0.65% of Nb, 0˜less than 0.10% of Mo, 0.8˜2.0% of Cu, 0˜0.10% of Al, 0.0005˜0.02% of B, 0˜0.20% of V, and 0.03% or less of N, with the balance being Fe and inevitable impurities, has a chemical composition satisfying the following equations (1) and (2), and has a structure in which ε-Cu phase grains, each having a long diameter of 0.5 μm or more, are present in a density of 10 or less per 25 μm 2 .
[0000] Nb−8(C+N)≧0 (1)
[0000] 10Si+20Mo+30Cu+20(Ti+V)+160Nb−(Mn+Ni)≧100 (2)
[0014] The lower limit of 0% of Mo, Al and V indicates the case in which the contents of these elements are below the measurable limit in a typical analysis method in a steel-making process. The presence of an ε-Cu phase may be confirmed through the observation of the cross-section (C-cross-section) of a specimen perpendicular to the rolling direction of a steel sheet using a transmission electron microscope. Into the elements of the equations (1) and (2), the contents of corresponding elements, represented by mass %, are substituted.
[0015] In addition, the present invention provides an automotive exhaust-gas path member formed using the above steel sheet. The path member is manufactured by subjecting the steel sheet, for example, the steel plate, to a process of forming a pipe, such as bending or welding. The automotive exhaust-gas path member is, for example, an exhaust manifold, a catalyst converter, a front pipe, or a center pipe. Particularly useful is a member that is heated to temperatures of 700° C. or higher while the engine is running and is then cooled to 400° C. from the increased temperature at an average cooling rate of 0.1˜30° C./sec after the engine is stopped.
[0016] According to the present invention, the thermal fatigue properties of the ferritic stainless steel sheet may be considerably improved without the use of expensive elements, including Mo. This steel sheet has a reasonable component design, which obviates the need for an excessive increase in high-temperature strength in the high-temperature range exceeding 700° C., and exhibits excellent durability in end uses, in which heating to the high-temperature range exceeding 700° C. and cooling to room temperature are repeated. The steel sheet, which is provided in the form of a steel plate, may be subjected to bending or welding to form a pipe, and has good low-temperature toughness. Thus, the ferritic stainless steel sheet is suitable for use in the automotive exhaust-gas path member, in particular, in the upstream member, which is heated to temperatures exceeding 700° C. The automotive exhaust-gas path member using such a steel plate may realize both low material costs and increased durability and reliability.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Typically, a ferritic stainless steel sheet for use in an upstream member of an automotive exhaust-gas path, for example, a member exposed to high temperatures exceeding 700° C. or 800° C., has been designed to have components in particular consideration of increasing high-temperature strength and oxidation resistance in such a high-temperature range. For this, the addition of expensive elements is inevitable and material costs are unavoidably increased.
[0018] However, according to the detailed investigation by the present inventors, in end uses in which heating to the high-temperature range and cooling to room temperature are frequently repeated, as in the automotive exhaust-gas path member, in the case where the durable lifetime of the member is considered, the improvement of thermal fatigue properties in the intermediate temperature range of 500˜700° C. has been found to be more important than the increase in high-temperature strength in all temperature ranges from 500° C. to, for example, 900° C., in order to increase durability and reliability and to decrease costs.
[0019] In the present invention, with the aim of improving the thermal fatigue properties of the steel sheet, in ferritic steel containing Cu, the precipitation of the ε-Cu phase is used. For instance, in ferritic stainless steel containing about 1˜2 mass % of Cu, because the ε-Cu phase is precipitated in the intermediate temperature range around 600° C., it is possible to manifest a precipitation strengthening phenomenon upon fine dispersion of the precipitate in a matrix. When the temperature exceeds about 900° C., the solid solution of the ε-Cu phase in the matrix is formed. Furthermore, in the subsequent cooling process, the above phase is precipitated again.
[0020] There have been conventional examples for strengthening the intermediate temperature range using the precipitation of the ε-Cu phase (Japanese Patent No. 3468156 and WO 03/004714). In these cases, however, thermal fatigue properties are not always improved stably upon the application of such a steel sheet to the upstream member of the automotive exhaust-gas path, resulting in unsatisfactory reliability. In order to solve these problems, the present inventors have conducted extensive investigation, resulting in the finding that the metal structure state of a steel sheet, in the step (hereinafter, referred to as “initial step”) before the steel sheet is mounted to the automotive exhaust-gas path and subjected to first heating and cooling hysteresis, has a great influence on the thermal fatigue properties in subsequent uses thereof.
[0021] That is, in the case where the material for a steel plate is formed into the upstream member of the automotive exhaust-gas path, the steel plate, before it is formed into the member, should preferably have a structure state in which ε-Cu phase grains, each having a long diameter of 0.5 μm or more, are present in a density of 10 or less per 25 μm 2 , and more preferably, 5 or less per 25 μm 2 .
[0022] In the case where the density of ε-Cu phase grains, each having a long diameter of 0.5 μm or more, exceeds 10 per 25 μm 2 , when the formed member is first heated for actual use, for example, when it reaches a temperature for engine starting, which is not lower than 800° C., the solid solution of the ε-Cu phase in the matrix may not be sufficiently taken place. In this case, when the engine is stopped, cooling is initiated in the state in which the ε-Cu phase exists in a considerable amount. Thereby, in the cooling process, because new ε-Cu phase grains are precipitated using the surface of the already-existing ε-Cu phase as a main precipitation site, precipitation strengthening through fine dispersion is not sufficiently exhibited. That is, the strength in the cooling process, which affects the thermal fatigue properties, is not sufficiently assured. Further, in the subsequent heating process, heating is initiated in a structure state in which the coarse ε-Cu phase is present. Consequently, in the subsequent course of repeated heat cycles of heating and cooling, the structure state in which the ε-Cu phase is finely dispersed is seldom realized even after a considerably long period of time, making it impossible to achieve an improvement in thermal fatigue properties.
[0023] In the initial step, the ε-Cu phase grains, each having a long diameter of 0.5 μm or more, are preferably present in a density of 0 per 25 μm 2 (i.e. not actually observed). However, it doesn't matter if ε-Cu phase grains, each having a smaller size, are present in a state of being dispersed in the matrix. Even when such a fine ε-Cu phase is present, it is subjected to solid solution again in the first heating process of the exhaust-gas path member, and the ε-Cu phase is finely precipitated in the matrix in the cooling process subsequent thereto, thus exhibiting precipitation strengthening.
[0024] The structure state in which the density of the ε-Cu phase grains each having a long diameter of 0.5 μm or more is adjusted to be 10 or less per 25 μm 2 is obtained by increasing the cooling rate of final annealing, which is conducted in the steel-making process. However, when the cooling rate is too high, Cu undesirably enters a complete solid solution state, instead of a structure state in which fine ε-Cu phase is dispersed. According to experiments by the present inventors, in the continuous line for the process of manufacturing the ferritic stainless steel plate having the composition mentioned below, when final annealing is conducted through soaking at 950˜1050° C. for 0˜60 sec, the average cooling rate to 400° C. from 900° C. is controlled to 10˜30° C./sec, thereby affording a preferable structure state.
[0025] Below, the components for steel are described.
[0026] C and N are elements that are effective in increasing high-temperature strength, including creep strength. However, when these elements are present in excessive amounts, oxidation properties, workability, low-temperature toughness, and weldability are decreased. In the present invention, the contents of both C and N are limited to 0.03 mass % or less.
[0027] Si is effective in improving high-temperature oxidation properties. However, when this element is used excessively, hardness is increased and workability and low-temperature toughness are decreased. In the present invention, the content of Si is limited to 1.0 mass % or less.
[0028] Mn functions to improve high-temperature oxidation resistance, in particular, scaling resistance. However, excessive addition thereof deteriorates workability and weldability. Further, because Mn is an element capable of stabilizing austenite, a large addition thereof enables the easy formation of martensite, undesirably decreasing thermal fatigue properties and workability. Thus, the content of Mn is set to be 1.5 mass % or less.
[0029] Cr functions to stabilize a ferritic phase and to improve oxidation resistance, which is important for high-temperature materials. However, when excessive Cr is added, the steel sheet becomes brittle or has deteriorated workability. Thus, the content of Cr is set to be 10˜20 mass %. The content of Cr is preferably adjusted to be suitable for the usage temperature of the material. For example, in the case in which outstanding high-temperature oxidation resistance to 950° C. is required, the content of Cr is preferably set to be 16 mass % or higher. Further, in the case in which resistance to 900° C. is required, Cr is preferably used in the range of 12˜16 mass %.
[0030] Ti is effective in improving formability. Although the mechanism thereof has not definitely been established, it is assumed that, base on the viewpoint in which the formability of a cold-rolled annealed plate is remarkably increased when an Nb—Ti-based precipitate is produced upon the thermal treatment of a hot-rolled plate, this precipitation phenomenon contributes to the formation of a texture structure in which the plane (111) or (211) is integrated parallel to the rolled surface, as the texture structure efficient for improving the formability. Although it is not definite that the precipitate itself functions directly, it is believed that the decrease in solid solution C due to the formation of the precipitate is connected therewith.
[0031] However, the excessive addition of Ti results in the deterioration of surface properties, attributable to the formation of TiN, and negatively influences weldability and low-temperature toughness. The content of Ti is set to be 0.05˜0.30 mass %.
[0032] Nb is an element that is very effective in assuring high-temperature strength in the high-temperature range exceeding 700° C. This element is considered to greatly contribute to the present component system through solid solution strengthening. However, when the content of Nb is less than 0.51 mass %, thermal fatigue strength is not satisfied. On the other hand, the excessive addition of Nb undesirably results in decreased workability and low-temperature toughness and increased hot cracking sensitivity of welds. Therefore, the upper limit of the content of Nb is set to be 0.65 mass %.
[0033] Mo is effective in enhancing high-temperature strength, but the present invention eliminates the need for expensive Mo. The addition of large amounts of Mo deteriorates workability, low-temperature toughness, and weldability. The content of Mo is limited to less than 0.10 mass %.
[0034] Cu is an important element in the present invention. As mentioned above, in the present invention, fine dispersion and precipitation of the ε-Cu phase facilitate the increase of the strength in the intermediate temperature range of 500˜700° C. and of the thermal fatigue properties. Thus, at least 0.8 mass % of Cu should be contained. However, the addition of excessive Cu results in decreased workability, low-temperature toughness, and weldability. The upper limit of the content of Cu is set to be 2.0 mass %.
[0035] Al functions as a deoxidant and acts to improve high-temperature oxidation resistance. However, when Al is contained in a large amount, it negatively affects surface properties, workability, weldability, and low-temperature toughness. Thus, in the case where Al is added, the content thereof is limited to 0.10 mass % or less.
[0036] B is effective in improving resistance to secondary working brittleness. The mechanism thereof is assumed to be due to the decrease in solid solution C at grain boundaries or the strengthening of the grain boundaries. However, the addition of excessive B worsens manufacturing ability or weldability. In the present invention, the content of B is set in the range of 0.0005˜0.02 mass %.
[0037] V contributes to increasing high-temperature strength along with the addition of Nb and Cu. Due to the co-existence with Nb, workability, low-temperature toughness, grain-boundary corrosion sensitization resistance, and toughness of weld heat affected zones are improved. However, the excessive addition thereof worsens workability and low-temperature toughness. Thus, in the case where V is added, the content thereof is set in the range of 0.20 mass % or less. The content of V is preferably set to be 0.03˜0.20 mass %, and more preferably 0.04˜0.15 mass %.
[0038] While individual elements are added in the ranges mentioned above, their contents are adjusted to satisfy the following equations (1) and (2).
[0000] Nb−8(C+N)≧0 (1)
[0000] 10Si+20Mo+30Cu+20(Ti+V)+160Nb−(Mn+Ni)≧100 (2)
[0039] Here, the equation (1) is prescribed to assure Nb in solid solution, and the equation (2) is prescribed to assure fundamental high-temperature strength.
[0040] The ferritic stainless steel sheet of the present invention may be manufactured by preparing steel having the above composition using melting and then subjecting the prepared steel to a series of processes of hot rolling, annealing, and acid pickling, or an additional series of processes of cold rolling, annealing, and acid pickling, once or several times. In order to obtain the precipitated form of the ε-Cu phase, in final annealing, the average cooling rate to 400° C. from 900° C. is preferably set within the range from 10˜30° C./sec. Here, the final annealing is the last annealing in the steel-making process, and, for example, may be conducted through soaking at 950˜1050° C. for 0˜3 min.
[0041] The steel sheet thus obtained is subjected to forming or welding, thus producing an automotive exhaust-gas path member. For example, in the case of the exhaust manifold or front pipe, a steel plate having a desired thickness is welded, and may be subjected to bending depending on the need, thereby obtaining a desired member.
[0042] According to the present invention, the thermal fatigue properties of the ferritic stainless steel sheet may be drastically improved, without the use of the expensive element, such as Mo. This steel sheet has a reasonable component design to avoid the excessive increase in the high-temperature strength in the high-temperature range exceeding 700° C., and may exhibit excellent durability in end uses in which heating to the high-temperature range exceeding 700° C. and cooling to room temperature are repeated. Further, the steel sheet, which is provided in the form of a steel plate, may be subjected to bending or welding, resulting in good low-temperature toughness. Therefore, the ferritic stainless steel sheet is preferably used for the automotive exhaust-gas path member, in particular, the upstream member, which is heated to temperatures exceeding 700° C. The automotive exhaust-gas path member using the steel plate may realize both low material costs and high durability and reliability.
Example
[0043] Ferritic stainless steel, shown in Table 1, below, was prepared using melting, and was then subjected to hot rolling, hot-rolled plate annealing, cold rolling, final annealing, and then acid pickling, thus obtaining an annealed steel plate having a thickness of 2 mm. In addition, part of a cast slab was subjected to hot forging, thus producing a round bar having a diameter of about 25 mm, which was then subjected to final annealing. Final annealing after the cold rolling and final annealing after the hot forging were conducted for all of the specimens, other than the steel No. 10, by maintaining the temperature of 1000° C. for 1 min and then adjusting the average cooling rate to 400° C. from 900° C. to 10˜30° C./sec. For the steel No. 10, maintaining the temperature of 1000° C. for 1 min and then adjusting the average cooling rate to 400° C. from 900° C. to about 50° C./sec were conducted (common conditions for rolled plate and bar).
[0000]
TABLE 1
(Mass %)
Steel
C
Si
Mn
Ni
Cr
Mo
Cu
Ti
Nb
V
Al
B
N
Equation(1)
Equation(2)
Inventive
1
0.002
0.33
0.25
0.02
17.80
0.01
1.66
0.10
0.30
0.03
0.01
0.0005
0.003
0.3
103.6
steel
2
0.009
0.25
0.11
0.09
16.08
0.01
1.40
0.25
0.38
0.05
0.02
0.0010
0.008
0.2
111.3
3
0.010
0.29
0.20
0.11
10.85
0.01
1.90
0.14
0.25
0.20
0.01
0.0050
0.009
0.1
106.6
4
0.009
0.45
0.33
0.10
16.89
0.06
0.84
0.18
0.45
0.15
0.01
0.0037
0.007
0.3
109.1
5
0.009
0.87
0.69
0.10
17.70
0.00
1.60
0.20
0.26
0.04
0.00
0.0026
0.007
0.1
102.3
6
0.010
0.33
1.16
0.10
14.05
0.00
1.50
0.28
0.30
0.06
0.00
0.0011
0.007
0.2
101.8
7
0.009
0.46
0.54
0.10
18.90
0.00
1.36
0.08
0.35
0.03
0.00
0.0030
0.007
0.2
103.0
8
0.009
0.66
0.32
0.10
14.85
0.02
1.66
0.15
0.35
0.07
0.02
0.0023
0.007
0.2
116.8
9
0.011
0.28
0.98
0.10
17.06
0.02
0.90
0.27
0.46
0.05
0.03
0.0032
0.006
0.3
109.1
10
0.006
0.88
0.30
0.02
10.88
0.01
1.15
0.26
0.35
0.04
0.02
0.0023
0.007
0.2
105.2
Comparative
11
0.010
0.35
0.22
0.11
17.50
0.01
0.75*
0.15
0.35
0.00
0.08
0.0000*
0.008
0.2
84.9*
steel
12
0.009
0.30
0.25
0.37
18.06
0.01
2.50*
0.18
0.32
0.07
0.01
0.0000*
0.014
0.1
133.8
13
0.009
0.55
0.26
0.14
16.80
0.00
1.40
0.08
0.01*
0.04
0.02
0.0000*
0.009
−0.1*
51.1*
14
0.035*
0.30
0.15
0.10
18.06
0.00
1.45
0.06
0.40
0.03
0.01
0.0009
0.004
0.1
112.1
15
0.010
1.36*
0.32
0.09
14.68
0.00
1.35
0.22
0.38
0.03
0.00
0.0022
0.009
0.2
119.5
16
0.007
0.25
0.22
0.10
16.00
1.50*
0.50*
0.00
0.30
0.03
0.01
0.0014
0.008
0.2
95.8*
17
0.008
0.15
1.89*
0.10
10.68
0.01
1.40
0.14
0.30
0.02
0.00
0.0017
0.008
0.2
92.9*
18
0.006
0.32
0.22
0.01
18.08
0.01
0.03*
0.10
0.35
0.02
0.01
0.0021
0.008
0.2
62.5*
19
0.009
0.33
0.80
0.11
14.25
0.00
1.40
0.10
0.30
0.04
0.21*
0.0000*
0.007
0.2
95.2*
20
0.010
0.45
0.28
0.09
16.66
0.00
1.36
0.15
0.36
0.03
0.01
0.0252*
0.010
0.2
106.1
*other than ranges prescribed in the present invention, wherein 0.00 is a content below the measurable limit
Equation(1): Nb—8(C + N)
Equation(2): 10Si + 20Mo + 30Cu + 20(Ti + V) + 160Nb—(Mn + Ni)
[0044] For the plate and bar after the final annealing, the metal structure on the cross-sections perpendicular to the rolling direction and the longitudinal direction thereof was observed. Using a transmission electron microscope, the size of the ε-Cu phase grains was measured, and the density of ε-Cu phase grains each having a long diameter of 0.5 μm or more was determined per 25 μm 2 . One specimen was observed at least ten times, and then an average value was determined. The case in which the density of ε-Cu phase grains each having a long diameter of 0.5 μm or more was 10 or less per 25 μm 2 was judged as “◯”, and the other case was judged as “X”. The results are shown in Table 2 below. Because there was no difference in the results of all steel for plates and bars, the ε-Cu content shown in Table 2 was evaluated to be suitable for both plates and bars.
[0045] A tensile test was conducted at room temperature using the plate, in order to evaluate workability. The tensile direction was divided into three types, that is, 0° (parallel), 45°, and 90° to the rolling direction. Using a JIS 13B specimen, a tensile test according to JIS Z2241 was conducted until breaking occurred, and after the breaking, two test pieces were butted to each other to thus measure elongation at the time of breaking. The average elongation EL A was determined from the following equation:
[0000] EL A =( EL L +2 EL D +EL T )
[0046] wherein EL L is the elongation (%) at 0° to the rolling direction, EL D is the elongation (%) at 45° to the rolling direction, and EL T is the elongation (%) at 90° to the rolling direction.
[0047] The case in which EL A was 30% or more was evaluated as “◯”, and the case in which EL A was less than 30% was evaluated as “X”.
[0048] An impact test was conducted using the plate, in order to evaluate low-temperature toughness. A V-notched impact specimen was prepared in a manner such that the impact direction coincided with the rolling direction of the plate, and the impact test according to JIS Z2242 was conducted at a pitch of 25° C. in the range of −75˜25° C., and a ductile-brittle transition temperature was determined. The case where the transition temperature was lower than −50° C. (ductile fracture surface was observed even at −50° C.) was evaluated as “◯”, and the case where the transition temperature was higher than −50° C. was evaluated as “X”.
[0049] A high-temperature continuous oxidation test was conducted using the plate, in order to evaluate high-temperature oxidation resistance. A 25 mm×35 mm specimen, the surface and cross-section of which were subjected to finishing through #400 wet polishing, was used. The high-temperature continuous oxidation test according to JIS Z2281 was conducted at 900° C. for 200 hours in an ambient atmosphere. After the test, the specimen was observed with the naked eye. The formation of a lump-shaped thick oxide scale was defined as abnormal oxidation, and the presence or absence of abnormal oxidation was observed. The case where abnormal oxidation was not observed was evaluated as “◯”, and the case where abnormal oxidation was observed was evaluated as “X”.
[0050] A high-temperature tensile test was conducted using the plate, in order to evaluate high-temperature strength. The high-temperature tensile test according to JIS G0567 was conducted at 600° C., and 0.2% proof stress was determined. The case not less than 180 MPa was evaluated as “◯”, and the case less than 180 MPa was evaluated as “X”.
[0051] A thermal fatigue test was conducted using the bar, in order to evaluate the thermal fatigue properties. A notched round bar specimen having a diameter of 10 mm in an un-notched cross-section and a diameter of 7 mm in a notched cross-section was manufactured. Under a constraint force of 20%, in an ambient atmosphere, a heat cycle, including 200° C.×0.5 min maintaining, heating to 900° C. at a heating rate of about 3° C./sec, 900° C.×0.5 min maintaining, and cooling to 200° C. at a cooling rate of about 3° C./sec, as one cycle, was repeated. The number of repeated cycles when the stress was decreased to 75% of initial stress was defined as thermal fatigue lifetime. The case where the thermal fatigue lifetime was 900 cycles or more was evaluated as “◯”, and the case where the thermal fatigue lifetime was less than 900 cycles was evaluated as “X”.
[0052] The results are shown in Table 2 below.
[0000]
TABLE 2
Steel
ε-Cu
low-temperature
high-temperature
high-temperature
thermal fatigue
Section
No.
content
workability
toughness
oxidation resistance
strength
properties
Inventive
1
∘
∘
∘
∘
∘
∘
examples
2
∘
∘
∘
∘
∘
∘
3
∘
∘
∘
∘
∘
∘
4
∘
∘
∘
∘
∘
∘
5
∘
∘
∘
∘
∘
∘
6
∘
∘
∘
∘
∘
∘
7
∘
∘
∘
∘
∘
∘
8
∘
∘
∘
∘
∘
∘
9
∘
∘
∘
∘
∘
∘
Comparative
10
x
∘
∘
∘
x
x
examples
11
x
∘
∘
∘
x
x
12
x
∘
x
∘
x
x
13
∘
x
x
∘
∘
∘
14
∘
x
x
∘
∘
∘
15
∘
x
x
∘
∘
∘
16
x
x
x
∘
∘
x
17
∘
x
∘
∘
∘
∘
18
x
∘
∘
∘
x
x
19
∘
∘
x
∘
∘
∘
20
∘
x
∘
∘
∘
∘
[0053] As is apparent from Table 2, the inventive examples satisfying the chemical composition and the precipitated form of the ε-Cu phase prescribed in the present invention had excellent thermal fatigue properties, and also had workability, low-temperature toughness, high-temperature oxidation resistance, and high-temperature strength suitable for use as the upstream member of the automotive exhaust-gas path. Although not shown in the above table, the inventive examples had a structure in which a fine ε-Cu phase having a long diameter less than 0.5 μm was dispersed in the matrix.
[0054] Although the steel No. 10 of the comparative examples had the chemical composition prescribed in the present invention, it had a cooling rate after the final annealing slower than 10° C./sec. Hence, the density of ε-Cu phase grains, each having a long diameter of 0.5 μm or more, exceeded 10 per 25 μm 2 , and the high-temperature strength at 600° C. and thermal fatigue properties were poor. The steel Nos. 11 and 18 had a low Cu content, and thus the ε-Cu phase was not sufficiently precipitated. Further, because the value of the equation (2) was small, high-temperature strength and thermal fatigue properties were poor. Because the steel No. 12 had too high Cu, the density of ε-Cu phase grains, each having a long diameter of 0.5 μm or more, exceeded 10 per 25 μm 2 , and high-temperature strength and thermal fatigue properties were poor. Moreover, the excessive addition of Cu resulted in insufficient low-temperature toughness. The steel No. 13 had a low Nb content, and undesirably unsatisfied the equation (1). The steel No. 14 had a high C content, the steel No. 15 had a high Si content, and the steel No. 16 had a high Mo content, resulting in poor workability and low-temperature toughness. In the steel No. 16, the content of Cu was much less, undesirably making it impossible to improve the thermal fatigue properties. The steel No. 17 had excessively high Mn, leading to poor workability. The steel No. 19 had poor low-temperature toughness due to its high Al content, and the steel No. 20 had poor workability due to excessively high B.
[0055] While the invention has been shown and described with respect to the preferred embodiments, it will be understood by those skilled in the art that various changes and modification may be made without departing from the spirit and scope of the invention as defined in the following claims. | Disclosed is a ferritic stainless steel sheet with excellent thermal fatigue properties, including, by mass %, 0.03% or less of C, 1.0% or less of Si, 1.5% or less of Mn, 0.6% or less of Ni, 10˜20% of Cr, 0.05˜0.30% of Ti, 0.51˜0.65% of Nb, 0˜less than 0.10% of Mo, 0.8˜2.0% of Cu, 0˜0.10% of Al, 0.0005˜0.02% of B, 0˜0.20% of V, and 0.03% or less of N, with the balance being Fe and inevitable impurities, having a composition satisfying the following equations (1) and (2) and having a structure in which ε-Cu phase grains each having a long diameter of 0.5 μm or more are present in a density of 10 or less per 25 μm 2 : Nb−8(C+N)≧0 . . . (1), 10Si+20Mo+30Cu+20(Ti+V)+160Nb−(Mn+Ni)≧100 . . . (2). The ferritic stainless steel sheet, having a relatively inexpensive component composition, has excellent thermal fatigue properties, and is suitable for use in an automotive exhaust-gas path member, including an exhaust manifold, a catalyst converter, a front pipe, or a center pipe. | 2 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application Ser. No. 60/574,899 filed May 26, 2004 entitled Two-Wire Power And Communications For Irrigation Systems which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to the combined powering, control and monitoring of sprinklers or other components of an irrigation system over a single set of two wires. More particularly, the apparatus of this invention transmits a square wave pulse train from a central location to remote components by alternating the polarity of the two wires with respect to each other. The pulses provide operating power to the components and at the same time can form a code which selects and operates a desired component. Operation of the component is monitored at the central location by sensing momentary current changes in the wires.
BACKGROUND OF THE INVENTION
[0003] Large commercial irrigation systems such as those used on golf courses or croplands use sprinklers, sensors or other components which are normally powered from 24 V AC power lines that can be several miles long and can serve many hundreds of components. Various schemes have been proposed for powering and controlling the components of such a system with just two wires. For example, U.S. Pat. No. 3,521,130 to Davis et al., U.S. Pat. No. 3,723,827 to Griswold et al., and U.S. Pat. No. 4,241,375 to Ruggles disclose systems in which sprinklers along a cable are turned on in sequence by momentarily interrupting the power or transmitting an advance signal from time to time.
[0004] A problem with this approach is that it does not allow the operator to freely turn on or off any selected sprinkler or set of sprinklers at different times. This problem is usually resolved by providing separate controllers in the field to operate groups of sprinklers in accordance with a program stored in them, or transmitted to them by radio or other means. Alternatively, it has been proposed, as for example in U.S. Pat. No. 3,578,245 to Brock, to operate individual sprinkler sets from a central location by superimposing a frequency-modulated signal or DC pulses onto the 24 V AC power line. All of these approaches are expensive, and the latter may cause electrolysis problems that can damage the system in the long run.
[0005] Finally, a system with hundreds of sprinklers stretched out over miles using conventional electric water valves requires expensive heavy wiring to accommodate the hold-open current drawn by a large number of valves that may be watering simultaneously.
[0006] It is therefore desirable to provide an irrigation system in which individual components connected to a two-wire cable can be turned on and off (or, in the case of a sensor component, read) from a central location at minimal cost, with a minimal expenditure of electrical power, and without causing any significant electrolysis problems in the system. It is also desirable to have the ability in such a system to monitor the successful execution of the on-off command, or to return data to the central location, without additional apparatus.
OBJECTS AND SUMMARY OF THE INVENTION
[0007] The present invention provides a way to both power and control a large number of devices connected to a two-wire cable by energizing the cable with a square wave consisting of power pulses of alternating polarity. When a device operation is desired, the system transmits a command pulse train consisting of a series of pulses separated by short no-power intervals. The polarity of each pulse in that series indicates whether it is a 1 or a 0 in a binary device identification and/or action code. The DC power of one or the other polarity available on the cable during each power or command pulse powers the decoder circuitry of each device and powers the desired operation of the device. The presence of power on the cable allows the selected device to signal receipt of the instruction by drawing a burst of current during the first pulse following the end of a command train. Electrolysis problems are minimized by the fact that statistically, the number of pulses of one polarity is about equal to the number of pulses of the opposite polarity.
[0008] If the command is an interrogation of a sensor such as a flow, temperature, soil moisture or rain sensor, the sensor transmits data to the central location by drawing current during one of the pulses of each set of alternating-polarity pulses following the command train. Current draw during a pulse of a first polarity signifies a “1”, while current draw during a pulse of the other polarity signifies a “0”. The absence of any current draw following any command indicates a system or component failure and can be used to trigger an alarm.
[0009] The system of this invention is fail-safe in that a valve actuating capacitor is continuously charged except during the actual actuation of the associated water valve solenoid. If power is lost, the capacitor discharges through the solenoid and puts the valve into the “off” state. Additionally, the decoders of this invention can be set to predetermined run times by the command pulse train, whereupon they will automatically shut the watering station off upon expiration of the commanded time.
[0010] By using latching solenoids actuated by the discharge of an actuating capacitor, power consumption of the system is minimized, and wiring as small as 14 gauge can successfully be used for cable runs of several miles controlling hundreds of watering stations or other devices.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 a is a block diagram showing the system of this invention;
[0012] FIG. 1 b is a block diagram of the motherboard of FIG. 1 a;
[0013] FIG. 1 c is a block diagram of a daughterboard of FIG. 1 b;
[0014] FIG. 2 a is a time-amplitude diagram showing the voltage on the cable while no commands are being transmitted;
[0015] FIG. 2 b is a time-amplitude diagram showing the voltage on the cable during the transmission of a command pulse train;
[0016] FIG. 2 c is a time-amplitude diagram showing the voltage and current on the cable following a water valve solenoid operating command;
[0017] FIG. 2 d is a time-amplitude diagram showing the voltage and current on the cable following a sensor interrogation command;
[0018] FIG. 3 a is a block diagram of a watering station decoder;
[0019] FIG. 3 b is a partial circuit diagram of the watering station decoder of FIG. 3 a;
[0020] FIG. 3 c is a partial circuit diagram showing the generation of a current burst; and
[0021] FIG. 4 is a block diagram of a sensor decoder.
DETAILED DESCRIPTION OF THE INVENTION
[0022] FIG. 1 a provides a general overview of the system 10 of this invention. An RS232 or other communication system 12 transmits action commands from a PC or other control unit 14 to a gateway 16 , and receives acknowledgments or other device information from the gateway 16 for conveyance to the control unit 14 . The gateway 16 , which in the preferred embodiment contains a motherboard 17 and a pair of daughterboards 19 a and 19 b, receives power from a power source 18 . As explained in more detail in connection with FIGS. 1 b and 1 c below, the function of the daughterboards 19 a,b is to selectively apply, in the preferred embodiment, the following potentials to the wires A and B of their respective cables 20 : 1) +40 VDC on A with respect to B; 2) +40 VDC on B with respect to A; or 3) an equal potential on both A and B. The daughterboards 19 a,b are also equipped to detect current drawn by the decoders of the system, and to report that information to the control unit 14 through the motherboard 17 . Device decoders such as watering station decoders 22 and sensor decoders 24 are connected in parallel to the wires A and B, and are arranged to operate the system components (e.g. water valves 26 or sensors 28 ) connected to them.
[0023] As best seen in FIG. 1 b, the motherboard 17 is powered from a line transformer 30 that steps the commercial AC voltage down to 28 VAC. Following surge protection at 21 in the preferred embodiment, this is applied to a bridge rectifier 32 which converts the
[0024] AC voltage to +40 VDC. This voltage is transmitted to the daughterboards 19 a and 19 b of FIG. 1 c through connector 23 . The output of bridge rectifier 32 is also applied to an operational amplifier 25 which provides incoming voltage information to the microprocessor 27 . In addition, the output of bridge rectifier 32 is applied to three sets of voltage regulators 29 a - c and isolation circuits 31 a - c which provide isolated 5 VDC power to the microprocessor 27 , the daughterboards 19 a,b, and the two-way isolation circuitry 33 , respectively.
[0025] The microprocessor 27 receives information from the control unit 14 through RS232 connector 35 as well as through an external pump pressure sensor 37 and an external rain sensor 39 ( FIG. 1 a ). Its outputs include a pump start signal 41 that controls the irrigation system's water pumps 43 , and a control signal 45 that operates the microprocessors 47 of the daughterboards 19 a and 19 b through the connector 23 . The microprocessor 27 may also provide appropriate outputs to operate LED indicators 49 to convey status information such as Watering In Progress, PC Connection Live, Power On, Transmitting Data, Receiving Data, Pump Pressure Normal, Rain Sensed, and Pump On. A communication line (Tx) connects the microprocessor 47 ( FIG. 1 c ) to the RS232 connector 35 through connector 23 and two-way isolation circuitry 33 for the transmission of commands and response data as described below.
[0026] FIG. 1 c shows the details of one of the two identical daughterboards 19 a and 19 b of FIG. 1 a. The +40 VDC line of the connector 23 is applied through the current sensor 38 to a Four-transistor H bridge 50 which is switched by microprocessor 47 , through an isolation circuit 51 , into the three possible output states of A-positive-with-respect-to-B, B-positive-with-respect-to-A, and A-and-B-at-same-potential. These are the states required by the protocol described below. A status LED 48 may be provided to monitor the operation of the microprocessor 47 . The wires A and B are preferably connected to the decoder cable 20 through a surge protector 57 .
[0027] The sensing of current by the current sensor 38 is conveyed to the microprocessor 47 through an isolation circuit 55 . A current pulse is detected when the current (in either direction) sensed by current sensor 38 rises through a predetermined threshold. The microprocessor 47 interprets this and conveys the appropriate information to the control unit 14 ( FIG. 1 a ) via the Tx line and the RS232 connector 35 .
[0028] A preferred protocol for the operation of the system of this invention is illustrated in FIGS. 2 a - d. Normally, the daughterboards 19 a, b impress a square wave 53 alternating between +40 V (A positive with respect to B) and −40 V (B positive with respect to A) across their respective outputs A and B at a 60 Hz rate. This provides a square-wave power supply ( FIG. 2 a ) to all the decoders 26 , 28 along the cable 20 . As pointed out below, the decoders 26 , 28 can use power of either polarity. Because the time of the circuit at one polarity is equal to its time at the other polarity, no electrolysis problem is generated.
[0029] If it is now desired to actuate a specific sprinkler or sensor, the command pulse train 52 shown in FIG. 2 b is transmitted. The command train begins with a no-power segment 54 in which the wires A and B are both grounded for 1/120 second. This is followed, in the preferred embodiment, by eight pulses 56 separated by similar no-power segments or delimiters 54 . The pulses 56 may be either +40 V (signifying a “1”) or −40 V (signifying a “0”). Taken together, the pulses 56 define the desired runtime (in minutes) of the device now to be selected.
[0030] The next twenty pulses 58 , again separated by no-power delimiters 54 , define the address of the desired device 26 or 28 . Next, the nature of the desired command is specified by the four pulses 60 . The command pulse train 52 illustrated in FIG. 2 b may, for example, convey the command “Turn Station 3 of decoder 2873 on for 25 minutes”. Upon completion of the command pulse train, the microprocessor 46 of FIG. 1 b returns control of the wires A and B to the power relays 40 , 42 . The output of gateway 16 thus resumes the square-wave format of FIG. 2 a.
[0031] If a selected decoder 26 has received and understood the command (see FIG. 2 c ), it momentarily draws a high current burst 62 during the +40 V portion of the first square wave 64 following the command pulse train. This is detected by the current sensor 38 of gateway 16 and constitutes an acknowledgement that the decoder has received its instruction. If no current is detected during the first square wave 64 , a control failure is indicated, and the microprocessor 46 may transmit an alarm to the control device 14 .
[0032] If the addressed device was a sensor decoder 28 (see FIG. 2 d ), the chosen decoder responds with current bursts 66 during the eight (in the preferred embodiment) square waves 68 following the command train. In each of these square waves, a current burst 70 during the +40 V portion transmits a “1” to the gateway 16 , while a current burst 70 during the −40 V portion transmits a “0”. As in the case of a station decoder 26 , the lack of any current burst during a square wave 68 indicates a system failure and may trigger an alarm.
[0033] An examination of FIGS. 2 a - d will show that in the preferred embodiment, a complete command and response cycle requires a little more than one second. Consequently, the described system can execute about fifty commands per minute.
[0034] FIG. 3 a illustrates a station decoder 22 used in the system of this invention. The power and communication signals from the gateway of FIG. 1 b appearing on wires A and B are applied to a bridge rectifier 72 that rectifies the incoming signals and conditions them to be interpreted by the microprocessor 74 . A power capacitor 76 is continually charged by the rectified power and communication signals in order to provide operating power to the microprocessor 74 through the no-power intervals 54 ( FIG. 2 b ), and long enough to perform an orderly shutdown in the event of a power failure.
[0035] The microprocessor 74 includes three subprocessors: the power manager 78 , the communications manager 80 , and the control manager 82 . The power manager 78 controls the charging of the actuating capacitor 84 whose discharge, under the control of control manager 82 , operates the station (i.e. watering valve) solenoids 86 a - d in the manner described below in connection with FIG. 3 b. An A/D converter 88 converts the charge level of the actuating capacitor 84 into a digital signal to allow control manager 82 to monitor the charge level of capacitor 84 . The power manager 78 controls the charging of capacitor 84 from the bridge rectifier 72 through an on/off switch 90 under the guidance of control manager 82 .
[0036] The communications manager 80 interprets any communication signals that appear at the bridge rectifier 72 , enables the bridge rectifier 72 to provide power to the on/off switch 90 if it determines the decoder 22 to have been selected, and informs the control manager 82 of the desired action. The communications manager 80 also controls the current drawn from wires A and B by the bridge rectifier 72 so as to produce the above-mentioned current burst 62 ( FIG. 2 c ) that acknowledges receipt of a command to the gateway 16 . The microprocessor 74 generates the current burst 62 by transmitting a pulse 87 ( FIG. 3 c ) which causes the output of bridge rectifier 72 to be momentarily bridged by a low-impedance resistor 89 through the source-drain circuit of transistor 91 .
[0037] The control manager 82 , pursuant to instructions from the communications manager 80 , operates triac output stages 92 a - d to actuate the solenoids 86 a - d and determines whether the solenoids 86 a - d are to be turned on or off. Its function is shown in more detail in FIG. 3 b, in which input 100 denotes the operating power from bridge rectifier 72 . Input 102 is the on/off signal from power manager 78 , with transistor 104 being driven by the on/off switch 90 . When switch 90 is on, power from input 100 can flow into the actuating capacitor 84 through transistor 104 . The voltage on capacitor 84 is monitored by the A/D converter 88 connected to output 106 .
[0038] When the solenoid 86 a is to be actuated, either by a received command or by the expiration of a runtime interval stored in the microprocessor 74 by pulses 56 ( FIG. 2 b ), the control manager 82 causes power manager 78 to turn off switch 90 so as to block transistor 104 , and applies power to input 108 . At the same time, the control manager 82 uses input 110 to switch triac bridge 92 a to the desired output polarity for turning the water valve 26 on or off. The capacitor 84 now discharges through the transistor 112 and the solenoid 86 a, opening or closing the water valve 26 depending upon the polarity of the output of triac bridge 92 a. The triac bridge 92 a also provides some degree of surge protection to the solenoid 86 a.
[0039] Following an actuation of the solenoid 86 a, the control manager 82 removes power from input 108 and directs the power manager 78 to turn switch 90 back on to recharge capacitor 84 . The control manager 82 will not execute an actuation command until the charge on capacitor 84 is back to a sufficient level. If a power failure occurs, the power manager, which continuously monitors the presence of power at the bridge rectifier 72 , causes the control manager 82 (which remains powered for a while by the power capacitor 76 ) to immediately go through a closing routine of all the water valves 26 as described above.
[0040] FIG. 4 illustrates a sensor decoder 24 according to the invention. The bridge rectifier 72 , microprocessor 74 , power capacitor 76 , power manager 78 and communications manager 80 serve the same functions as in the station decoder described above in connection with FIG. 3 a. In the sensor decoder 24 , however, the control monitor 82 of FIG. 3 a is replaced by a sensor manager 120 . The sensor manager 120 , when so commanded by the communications manager 80 , causes a sensor read circuit 122 to read and condition the sensor data which is continuously transmitted by the sensor 28 to the interface 124 . The interface 124 preferably contains surge components and, if appropriate, A/D conversion circuitry.
[0041] The data received by the sensor manager 120 is conveyed to the communication manager 80 and is used by it to produce the current bursts 66 ( FIG. 2 d ) that transmits the data to the gateway 16 .
[0042] Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof. | A large number of irrigation system devices connected to a common two-wire cable can be powered and individually controlled from a central location by transmitting over the cable DC pulses of alternating polarity. Control information is conveyed by transmitting a command pulse train consisting of a series of pulses, separated by short no-power intervals, whose polarities indicate logic ones or zeros. Following a command pulse train, a selected watering station decoder acknowledges receipt of instructions by drawing current during a predetermined pulse of an alternating-polarity power pulse cycle, while a sensor decoder returns binary data by drawing current during one or the other of the alternating-polarity pulses of a series of power pulse cycles. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a national stage of PCT/EP2004/009171 filed Aug. 16, 2004 and based upon German application DE 103 40 320.5 filed Aug. 29, 2003 under the International Convention.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The invention concerns a multi-part composite valve for an internal combustion engine.
[0004] In modern high power motors ever increasing demands are placed upon the high thermal loaded exhaust valves. The valve plate in particular is subjected to high mechanical and thermal loads. It has thus already been variously proposed to manufacture the value shaft and the valve plate of different materials and to join the two parts. Herein the valve shaft can be produced from a ductile material and the valve plate of a high temperature resistant and friction resistant material.
[0005] 2. Related Art of the Invention
[0006] In DE 100 29 299 C2 a multi-part composite valve for an internal combustion engine as described, which as already discussed, is produced by joining a valve shaft and a valve plate. This invention is however particularly directed towards the objective of using a hollow valve shaft, which is cooled for example using sodium. Valve shaft and valve plate are joined to each other in this arrangement preferably by laser welding or by hard soldering or brazing. In this process however all individual parts must be separately manufactured and subsequently joined to each other in an elaborate joining device.
SUMMARY OF THE INVENTION
[0007] The task of the invention is comprised therein, of providing a multi-part composite valve for an internal combustion engine, which compared to the state-of-the-art requires less product steps and a less elaborate production facility.
[0008] The solution of this task is comprised in a valve for an internal combustion engine.
[0009] The multi-part composite valve for an internal combustion engine includes a valve shaft and a valve plate. Both are produced separately and joined to each other in an overlapping area. The invention is characterized in the valve shaft in the transition area at least partially is provided with an intermediate layer, and that this bonded with the valve shaft as well as with the valve plate materially in the manner of a chemical bond. Further, the valve plate is cast onto the valve shaft.
[0010] The term “chemical bonding” is herein understood to mean a material fused bond, wherein the material of the layers is bonded with each other by reaction, by alloying or by diffusion. A material-to-material bond of this type can also be achieved purely by casting the valve plate onto the shaft. The joining behavior is however in this method dependent upon the employed materials until now insufficient or unsatisfactory. The inventive employed intermediate layer is so designed, that it bonds both with the material of the valve shaft as well as with the material of the valve plate forming a substance bond. Therewith a solid and rigid bonding between the valve shaft and the valve plate is produced. Since the valve plate is cast on, a laborious welding and brazing process is no longer necessary.
[0011] Depending upon the character or composition of the materials of the valve shaft and the valve plate this can sometimes be useful, that the intermediate layer is in the form of a gradient layer or a multiple layer. In this manner the mechanical characteristics (for example hardness, modulus of elasticity), the physical characteristics (for example co-efficient of expansion, thermal conductivity) and the chemical characteristics of the individual partial areas, the valve plate and the valve shaft, be taken advantage of.
[0012] For supporting the substance-to-substance joining it can be useful that supplementally a form fitting joint between the valve shaft and the valve plate is provided. This form fitting joining can have a design such as for example microscopic cutbacks in transition area.
[0013] It can likewise be useful to thermally or mechanically roughen the valve shaft in the transition area for formation of microscopic undercuts or recesses. The term “microscopic undercuts or recesses” are herein intended to include microscopic surface recesses which are introduced for example by material erosion or material displacement. The liquid material of the cast on valve plate embeds itself in these microscopic surface recesses, solidifies and forms a solid tight form fitting or as the case may be material-to-material joint.
[0014] In a preferred manner the intermediate layer or a chemical precursor layer is provided, prior to the casting on of the valve plate, upon the transition are of the valve shaft. The term “chemical precursor layer” is herein understood to be a layer, which during the melting on of the valve plate or by a subsequent thermal treatment changes its chemical composition at least in part.
[0015] In one design of the invention the valve plate is comprised of a aluminum-titanium composite. For this as a rule a stoichiomutric titanium-aluminide (TiAl) is preferred. This material is comprised of an inter metallic fusion for composite of titanium and aluminum. It is exceptionally high temperature resistant and exhibits thereby a high mechanical and tribologic strength.
[0016] The valve shaft in comparison is in contrast preferably produced in advantageous manner from a steel material. Steels are known for advantageous properties and low price and exhibit a comparatively high ductility.
[0017] The intermediate layer or at least a tier or layer is preferably comprised of an alloy having a silver base, nickel base, titanium base and/or copper base. This type of alloys are suited for example as hard brazing or soldering, that can be applied easily upon the valve shaft in known coating processes and form together therewith on the surface an alloy, which in accordance with this invention is considered a chemical joint.
[0018] The at least one intermediate layer or the chemical precursor layer can likewise in preferred manner be comprised on the basis of a metal oxide. This metal oxide can undergo a reaction, in particular a reduction reaction, upon melting on of the alloy elements of the valve plate during the melting on thereof, which leads to a more solid chemical joining between the valve plate and the metal oxide of the intermediate layer.
[0019] That the intermediate layer or the chemical precursor layer prior to casting on of the valve plate exhibits an open porosity. This open porosity comprises between one percent and seventy five percent. Preferably this porosity is between 5% and 25% and between 30% and 60%. Therein in advantageous manner the liquid metal, which later forms the valve plate, can penetrate into the porosity of the intermediate layer and react along the surface thereof. By the incorporation of the porosity the surface, which is available for the joining between the valve plate and the intermediate layer, is increased. At the same time it can be useful to provide the surface of the intermediate layer analogous to the surface of the valve shaft with microscopic recesses or undercuts by mechanical or chemical processing.
[0020] The invention is in the following described in greater detail on the basis of a few selected working examples in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Therein there is shown:
[0022] FIG. 1 : a cross section through a valve with a valve shaft and a cast on valve plate, which in the transition area exhibits an intermediate layer,
[0023] FIG. 2 : a cross section through a valve with a valve shaft and a cast on valve plate, which in the transition area exhibits an intermediate layer,
[0024] FIG. 3 : an enlargement of the detail III from FIG. 1 with the schematic representation of an intermediate layer in the form of a gradient layer, and
[0025] FIG. 4 : an enlarged representation of the detail IV of FIG. 2 , a schematic representation of an intermediate layer in the form of a multiple layer.
DETAILED DESCRIPTION OF THE INVENTION
[0026] In FIG. 1 the cross section through a valve 1 is schematically represented, wherein the valve 1 includes a valve shaft 2 and a valve plate 4 . In a transition area 6 of the valve shaft 2 and the valve plate 4 the valve shaft 2 is provided with ring shaped undercuts 14 . Besides this the valve shaft 2 exhibits in the overlapping area 6 and intermediate layer 8 .
[0027] the valve plate is cast on the valve shaft 2 . In the transition area 6 the valve plate 4 and the valve shaft 6 are materially joined to each other via the intermediate layer 8 . For supporting the material-to-material bonding via the intermediate layer 8 the valve plate 4 and the valve plate shaft 2 are additionally form fittingly joined by the recesses 14 and therewith supplementally secured.
[0028] In FIG. 2 an analogous representation of a valve 1 with a valve shaft 2 and a valve plate 4 is shown. Conceptually the same parts are given basically the same reference numbers. Also the valve 1 in FIG. 2 exhibits a recess 14 in the form of a sphere or a drop, which in the overlapping area 6 is fixed to the valve shaft 2 . Likewise in this embodiment an intermediate layer 8 is provided, which joins the valve plate 4 and valve shaft 2 materially via chemical joining to each other.
[0029] The incorporation or introduction of recesses 14 , which are shown in FIGS. 1 and 2 , is for ensuring an optimal joining between the valve shaft 2 and the valve plate 4 not absolutely necessary however sometimes useful. In the recesses 14 in the FIGS. 1 and 2 these are basically two arbitrary examples. It is besides this conceivable that the recesses 14 are for example in a form of a spiral in the overlap area 6 of the valve shaft 2 . For this all processes could be employed, which in conventional manner can be employed for producing a thread. Further, designs of recesses 14 in the overlap area 6 could be notches, grooves, corrugations, channels or bores.
[0030] It is further useful that the valve shaft 2 is treated in the overlap area 6 mechanically for example by sand blasting or by grit blasting. Thereby a surface roughness is increased in the overlap area 6 , which improves the application and the attachment of the intermediate layer 8 .
[0031] The intermediate layer 8 can basically be comprised of one or more functional layers. For this it follows that basically one or more different types of application process can be employed for the individual tiers or strata of the intermediate layer 8 . Typical application processes are for example thermal spray processes such as plasma spraying, flame spraying, arc wire spraying or kinetic cold gas pacting. Further, thin coating techniques such as CVD, PVD or sputtering, painting and spray processes or galvanic processes can be employed. Further, the application of for example a metal alloy by a dip bath or by a soldering film, which is further melted in a soldering oven, conceivable.
[0032] As materials for the coating there come into consideration a high temperature resistant metal alloy, in particular based on silver, based on nickel, based on titanium, or based on copper. This type of alloy can also be employed as a hard solder or brazing solder are however applied in the present case for example by a thin layer technique or galvanic technique or by a dip bath or as the case may be by a later melted film coating upon the overlapping area 6 . This type of alloys introduce upon the application of an external energy an alloy with the surface of the valve shaft 2 . The alloy or amalgamate according to this, which by definition is considered as a chemical joint. Upon melting on of the valve plate 4 the materials alloy begin with the valve plate material, which is at this time in molten, at least however in softened form, and forms therewith a chemical joint in the form of an alloy or in the form of intermetallic phases.
[0033] A further variant of layer materials comprises the application of reactive metal compounds for example metal oxides. This type of metal oxide can be produced for example by a thermal spray process or by laser centering of an applied ceramic slip. This type of thermal spray process is particularly economic from a production technology perspective. As an example for a suitable metal oxide one could name titanium oxide (TiO2). In the use of a valve plate material on the basis of TiAl the TiO2 undergoes a exothermic chemical reaction with the aluminum of the TiAl melt. The chemical reaction proceeds according to the following equation: “x TiO2+y Al+Ti->A12o3+TiaAlb.”
[0034] The provided reaction equation is not stoiciometrically. It is however noted that by the nickel reaction the molten aluminum is drawn upon for formation of the aluminum oxide. For ensuring a stoiciometric composition of the valve plate 4 on the basis of Ti:Al=1:1, it is preferred to supply in the melt and stoiciometric excess of aluminum.
[0035] The reaction product titanium oxide and TiaAlb, which forms the intermediate layer 8 according to this reaction, forms a homogonous dense layer, which chemically is joined with the valve plate 4 . By the exothermic energy, which is released during the above mentioned reaction, also a surface reaction with the surface of the valve shaft 2 occurs. The thermal sprayed or as the case may be laser centered metal oxide can be considered as a chemical precursor layer for the intermediate layer 8 .
[0036] The above explanations basically are intended to represent one example of a reaction system, by means of which a chemical bound transition layer 8 is producible. Basically all further reaction systems, which undergo an exothermic reaction with the melt material of the valve plate 4 can be employed as the basement material and chemical precursor layer for the transition layer 8 . These include for example also the carbides, nitrides and borides of the adjacent metal.
[0037] Basically, after the casting on of the valve plate 4 onto the valve shaft 2 a further thermal treatment can occur, which can serve to support the formation of a chemical bonding between the intermediate layer 8 on the one hand and the valve plate 4 or as the case may be the valve shaft 2 .
[0038] For ensuring a balance of the various physical material characteristics of the valve shaft material and the valve plate material, it can be useful to utilize a multi-strata layer 12 ( FIG. 4 ) or a gradient layer 10 ( FIG. 3 ) as the transition layer 6 . Herein reference can be made back to the already described base principles of the types of application of the layer materials and their manner of reaction. In FIGS. 3 and 4 illustrative examples for a gradient layer 10 or as the case may be for a multi-strata layer 12 are shown.
[0039] In FIG. 3 a gradient type transition layer 6 is shown, which is based for example on the basis of a high temperature solder AgCu 13 . The solder material AgCu 13 is applied in a dip bath upon the overlap area 6 of the valve shaft 2 . But the energy exhibited by the liquid melt, the chemical reaction in the form of an alloying occurs in area 16 . This is a superficial alloying of the steel of the valve shaft 2 and the AgCu 13 alloy. In FIG. 3 this area is indicated bordered by two dashed lines and schematically by a decreasing gray area, During the melting on of the valve plate 4 in turn so much thermal energy from the melt is applied, to the AgCu 13 layer material undergoes an alloying with the TiAl material of the valve plate 4 . Also here there results a gradient shaped transition area 16 in which the individual alloy components are present in the form of intermetallic phases or in the form of alloy. As further layer composition the material of the valve plate 4 continues in pure form.
[0040] A further useful alloying system is comprised on the basis of nickel and exhibits for example the following composition: 7 wt. % Cr, 3 wt. % Fe, 4, 5 wt. % Si, 3, 2 wt. % B as well as Rest Nickel.
[0041] The chrome content of this alloy can be varied between 7 wt. % and 19 wt. %, the silicon coating can vary between 4.5 wt. % and 7.5 wt. %.
[0042] The material is preferably applied in the form of a film or foil and melted in the overlap area 6 of the valve shaft 2 .
[0043] If a chemical bonding of the shaft material and plate material can not be ensured by a bonding alloy, as indicated for example in the form of AgCu 13 , then it can be useful, analogous to FIG. 4 to apply a further supplemental layer 18 in the form of thermal spray layer of titanium oxide.
[0044] The intermediate layer 8 from FIG. 4 is in the form of a multi-strata layer 12 . Herein analogous to FIG. 3 first in the overlap area 6 of the valve shaft 2 a metallic alloy, in this case by galvanic coating, is applied, upon which next a titanium oxide layer can be applied by thermal spray processes, in this case by an arc wire spraying. The galvanic application method there forms between the material of the valve shaft 2 and the galvanic applied alloy material 17 an alloy in the form of a solid rigid chemical bond. The thermal spray layer 18 , which essentially is comprised of a titanium oxide, exhibits a porosity, which can be adjusted by process parameters, is 55%. During melting on of the valve plate 4 the liquid TiAl material is drawn by capillary forces into the pores of the porous layer 18 , or upon this leads to an exothermic reaction to the above provided reaction equation. In the area of the layer 18 there forms in accordance with the reaction an aluminum oxide/TiAl material, which is solidly chemically bonded with the TiAl material of the valve plate 4 . In the intermediate layer 8 shown in FIG. 4 there is represented a combination of a multi-strata layer 12 and a gradient layer 10 . This complex construction is suited for balancing the physical and mechanical characteristics between the valve shaft material and the valve plate material. This includes in particular the thermal co-efficient of expansion. However also electrochemical characteristics can make it necessary to employ the multiple layers. By the application of a thermal sprayed layer it is possible also to influence the surface structure of the layer for example. By adjusting the spray parameters a suitably roughened surface can be adjusted for the melting on of the valve plate 4 . | The invention relates to a multipart composite valve for an internal combustion engine, in which a valve shaft ( 2 ) and a valve plate ( 4 ) are embodied separately while being joined together in an overlapping area ( 6 ). The invention is characterized in that at least some parts of the valve shaft ( 2 ) are provided with an intermediate layer ( 8 ) in the overlapping area ( 6 ). Said intermediate layer ( 8 ) forms an integral joint with both the valve shaft ( 2 ) and the valve plate ( 4 ) in the form of a chemical bond, the valve plate ( 4 ) being cast onto the valve shaft ( 2 ). | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/508,461, filed Oct. 2, 2003.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of handheld power tools, specifically to the adaptation of linearly reciprocating handheld power tools to multiple uses.
2. Prior Art
A reciprocating handheld power saw is a tool that is widely used by plumbers, electricians, carpenters, and other workers in the construction industry. (See, for example, the listing for Milwaukee 10 Amp Sawzall Reciprocating Saw in “Milwaukee Product Catalog”, Milwaukee Electric Tool Corporation, [retrieved on 2003 Aug. 21], retrieved from <URL:http://www.milwaukeeconnect.com/html/index.html>.) The saw blades of such tools are generally removable. This makes it possible to apply the linearly reciprocating motion of such a power tool to other applications besides cutting with a saw.
In U.S. Pat. No. 6,142,715, “File Adapter for Power Saw Tool”, to Fontaine, a reciprocating handheld power tool is adapted to become a power filing device. The disclosed apparatus requires two points of connection between the filing adapter and the power tool. A bar holding the file is connected to the reciprocating portion of the power tool. A bracket for guiding the reciprocating file is connected to the body of the power tool. The result is a relatively complex construction dedicated to the application of power filing.
In U.S. Pat. No. 4,893,437, “Power Sanding Adapter for Jigsaws”, to Doherty, a reciprocating handheld power tool is adapted to scrape or sand wallpaper from a wall. The disclosed apparatus requires two points of connection between the sanding adapter and the power tool. A bar holding a scraping or sanding head is connected to the reciprocating portion of the power tool. A bracket for guiding the reciprocating portion and providing additional hand-holds is connected to the body of the power tool. The result is a relatively complex construction dedicated to the application of scraping or sanding.
Each of the two patented inventions described above are dedicated to a narrow range of application. Each requires a relatively complex connection to a power tool so that reconfiguration of the power tool for multiple different applications in the field is cumbersome and inconvenient.
3. Objects and Advantages
The present invention adapts a linearly reciprocating handheld power tool to multiple applications including brushing, scraping, sanding, and polishing. It requires only a single point of connection between an attachment and the power tool. It enables very fast and convenient reconfiguration for the multiple supported applications.
SUMMARY OF THE INVENTION
An adapter connects to a reciprocating handheld power tool at the single point of connection typically used to attach a saw blade. The adapter provides a flange that fits into multiple different application attachments using a simple and convenient press-fit mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an adapter with a brush attachment connected to a reciprocating handheld power tool.
FIG. 2 is a perspective view of an adapter.
FIG. 3 is a close-up view of the universal tang protruding from the adapter where it connects to a reciprocating handheld power tool.
FIG. 4 is three views of the base of an attachment.
FIG. 5 is a scraper attachment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Structure and Operation
The present invention adds multiple additional functions to a reciprocating handheld power tool, such as the Milwaukee Sawzall. (See, for example, the listing for Milwaukee 10 Amp Sawzall Reciprocating Saw in “Milwaukee Product Catalog”, Milwaukee Electric Tool Corporation, [retrieved on 2003 Aug. 21], retrieved from <URL:http://www.milwaukeeconnect.com/html/index.html>.) These tools are principally used with saw blades by construction workers for rough cutting applications.
FIG. 1 shows a typical reciprocating handheld power tool 10 configured with a wire brush attachment 25 instead of a common saw blade attachment. An operator typically places one hand on a hand grip 12 at the rear of power tool 10 , places the other hand under the middle of power tool 10 , and presses a trigger 14 . This activates the in-and-out motion of a reciprocating member 15 of power tool 10 , which causes wire brush attachment 25 to move back and forth in a scrubbing action on any surface on which it is placed. Power tool 10 thus substitutes for the human muscle power applied in manual brushing. One important use for this configuration is the removal of old paint from woodwork or other surfaces.
FIG. 1 shows that wire brush attachment 25 is connected to reciprocating member 15 using an adapter 20 . Adapter 20 is shown separately in FIG. 2 , displayed in an inverted position relative to FIG. 1 . Adapter 20 has an overall length of 21 centimeters. It is fabricated from three parts: a flat metal blade 30 , a main housing 35 , and a flange molding 40 .
Blade 30 is 0.18 centimeters thick and 9.9 centimeters long. A length of 7.2 centimeters of blade 30 is molded inside housing 35 . This portion of blade 30 is cut in a pattern of square teeth for firm anchoring. A length of 2.7 centimeters of blade 30 protrudes from housing 35 . This portion of blade 30 fits into reciprocating member 15 using the de-facto standard shape and size of the ½-inch universal tang (or shank) used at the connecting end of all Sawzall blades and compatible with many products competitive with the Sawzall. (See, for example, the listing for Super Sawzall Blade, 6 Teeth per Inch, 9 in. Length, in “Milwaukee Product Catalog”, Milwaukee Electric Tool Corporation, [retrieved on 2003 Aug. 21], retrieved from <URL:http://www.milwaukeeconnect.com/html/index.html>.) A close-up view of this end of blade 30 is shown in FIG. 3 .
Main housing 35 is composed of molded plastic. The overall length of housing 35 is 18 centimeters. The width of housing 35 is 0.8 centimeters. Housing 35 uses two truss webs to support flange molding 40 and to handle the stress forces of operation. A heel web 37 , which is closer to the connection to power tool 10 , is composed of two curved plastic portions that protrude about 6.5 centimeters above the straight bottom portion of housing 35 . A toe web 42 , which is farther from the connection to power tool 10 , is composed of two straight plastic portions that protrude about 5.0 centimeters above the straight bottom portion of housing 35 .
Flange molding 40 has a flat base that is 0.7 centimeters thick by 2.0 centimeters wide by 14.5 centimeters long. Centered on the top of this base is a rectangular flange that is 0.6 centimeters tall by 0.6 centimeters wide by 12.0 centimeters long. Flange molding 40 is composed of plastic. Flange molding 40 is precision molded so that it will form a reliable press fit into a corresponding cavity 65 in base 50 (see FIG. 4 ) of wire brush attachment 25 . Flange molding 40 may be rigidly fixed to truss webs 37 and 42 using glue, electrical welding, screws, or any other method that can handle the stress forces of operation. The plane of the flat base of flange molding 40 is angled six (6) degrees from the axis of reciprocation which runs through the length of flat blade 30 and the straight bottom portion of housing 35 . This angle allows for comfortable positioning of an operator's hands while brushing a large flat surface.
FIG. 4 shows details of base 50 of wire brush attachment 25 in three views: top, side, and end. Base 50 is composed of plastic. Base 50 is precision molded so that cavity 65 forms a reliable press fit with flange molding 40 of adapter 20 .
To form wire brush attachment 25 , stiff wire bristles are imbedded at regular intervals in the top of base 50 . However, many other useful attachments may be made from base 50 or minor variations of base 50 . Attachments may be made with brushes of various sizes, shapes, and materials. Attachments may also be made with scrapers, scouring pads, or buffing pads. Any work accomplished by a hand tool used with a reciprocating or scrubbing motion of a human arm may be eased by an attachment to a reciprocating handheld power tool according to the present invention. One example, a scraping tool attachment, is shown in FIG. 5 . The scraping tool attachment is formed by connecting a scraper blade 55 to base 50 . The base 50 of each different attachment has a cavity, such as 65 , for a quick and easy mounting on the support flange molding 40 and removal therefrom.
Conclusion and Variations
Adapter 20 connects to a reciprocating handheld power tool at a single point of connection using a simple established standard, such as the ½-inch universal tang used with any Milwaukee Sawzall and many compatible competitive products. The quick and easy press-fit connection of flange molding 40 into cavity 65 is very convenient for operators who need to quickly change from one application to another. Thus the present invention makes multiple applications of a reciprocating handheld power tool significantly faster and more convenient than it has been with prior art.
As an alternative, operators who work a single application for an extended period of time may prefer to have a particular attachment permanently attached to adapter 20 . This configuration is included in the scope of the present invention.
The ½-inch universal tang for connection to any Milwaukee Sawzall reciprocating handheld power tool and compatible competitive products appears to be the current preferred standard for connecting saw blades to reciprocating handheld power tools. Nevertheless, the end of blade 30 which protrudes from plastic housing 35 may be readily altered to make a variation of adapter 20 which attaches to other handheld reciprocating power tools that use a connection standard different from that of the Milwaukee Sawzall.
In the light of these and other possible variations of the preferred embodiment, the scope of the present invention should be determined not by the specific descriptions above, but by the following claims. | A construction worker may adapt a reciprocating handheld power saw to multiple additional applications including brushing, scraping, sanding, and polishing. A simple adapter is attached to the power tool in place of a saw blade. Multiple attachments for the various applications are easily press-fit onto the adapter. | 1 |
This invention was made with Government support under Contract DAMD17-86-C-6148 awarded by the Department of the Army. The Government has certain rights in this invention.
FIELD OF THE INVENTION
The present invention relates generally to neuronal α-bungarotoxin-binding proteins (αBgtBPs). More particularly, the present invention is directed to a family of vertebrate, such as avian or mammalian, neuronal αBgtBPs. In one aspect, the present invention relates to the isolation and sequencing of cDNA clones encoding two neuronal α-bungarotoxin-binding protein (αBgtBP) subunits: αBgtBP α1 and α2. The invention further relates to the identification and characterization of the α1 and α2 subunits, to the recognition and subtypes of αBgtBPs which use different α subunits, and to the expression of these subunits or their subsegments, as proteins in microorganisms or cell lines, particularly using recombinant DNA technology. In another aspect, the present invention concerns the use of cDNA clones encoding neuronal αBgtBP α1 and α2 subunits as probes that can, for example, identify further neuronal αBgtBP subunits. In a still further aspect, the invention relates to the use of neuronal αBgtBP and, in particular, the α1 and α2 subunits as diagnostic tools in the screening of cholinergic agents and other drugs that may affect the ligand binding, ion channel or other activity of intact neuronal αBgtBP subtypes.
BACKGROUND OF THE INVENTION
Since the neuronal αBgt binding proteins of the present invention and nicotinic acetylcholine receptors and certain other receptor types appear to be members of the same gene superfamily, it seems appropriate to start the review of background art with a brief overview of our recent knowledge of the known types of such receptors.
The study of cell to cell contacts known as synapses, has long been a focal point of neuroscience research. This is particularly true of the neuromuscular synapse (often called neuromuscular junction), which occurs at the point of nerve to muscle contact, primarily because of its accessibility to biochemical and electrophysiological techniques and because of its elegant, well defined structure. Much of this research has concentrated on acetylcholine receptors because they are a critical link in transmission of signals from nerves to muscles. Action potentials propagated along a motor nerve axon from the spinal cord depolarize the nerve ending causing it to release a chemical neurotransmitter, acetylcholine. Acetylcholine binds to nicotinic acetylcholine receptor proteins located on post-synaptic muscle cells, triggering the brief opening of a cation channel through the receptor molecule and across the postsynaptic membrane. The resulting flux of cations across the membrane triggers an action potential that is propagated along the surface membrane of the muscle, thereby completing neuromuscular transmission and ultimately causing contraction of the muscle.
Several lines of evidence demonstrate that nicotinic acetylcholine receptors (AChRs) of muscle, brain and ganglia, belong to the same family and function as acetylcholine (ACh)-gated cation channels.
The most well-studied member of this family is the muscle-type AChR of the electric organs of Torpedo californica and related species, because electric organs contain much larger amounts of nicotinic acetylcholine receptors than muscle. Muscle-type nicotinic AChRs are composed of four kinds of subunits, including two α subunits which contain the ACh-binding sites, and must be both liganded to efficiently trigger opening of the cation channel, and one each of β, γ and δ subunits. The subunits are oriented like barrel staves in the order of αβαγδ around the central cation channel whose opening is regulated by binding of ACh to the α subunits. All of the AChR subunits have sequence homologies throughout their lengths which suggests that they evolved by gene duplication from a common ancestor and have similar basic structures. Evolution of muscle-type AChRs has been quite conservative; there is 80% sequence homology between α subunits of AChRs of the electric organs of Torpedo californica and human muscle, and about 55% homology of the other subunits between these species. However, AChRs of different origin are much more antigenically distinct than their sequence homologies would suggest. A concise review of the structure and properties of muscle-type nicotinic AChRs is, for example, provided by Lindstrom et al, Mol. Neurobiol. 1(4), 281 (1987). Study of these receptors has been greatly enhanced by the availability of suitable molecular probes, in particular α-Bungarotoxin (αBgt). αBgt binds with great affinity to the ACh-binding sites of muscle-type nicotinic AChRs thereby inhibiting their function, and can be used as a histological label, affinity column ligand, and probe for the ACh-binding site of the purified AChRs. αBgt satisfies three criteria that certify it as a ligand for muscle-type AChRs: (i) its binding to muscle is saturable and agonists and antagonists of ACh compete for this binding; (ii) it binds to cells and regions of cells that respond physiologically to ACh; (iii) it blocks the physiological response of muscle to ACh.
Nicotinic acetylcholine receptors on neurons (neuronal nicotinic AChRs), that are members of the same ligand-gated cation channel family as muscle-type nicotinic AChRs, have originally been much less well characterized than have their muscle-type relatives. This was partly because there were no neural systems as convenient as muscle and there was no neural system that provided as much AChR as electric organs. Also, studies were hampered by lack of suitable molecular probes. As mentioned before, the snake toxin αBgt has proven an invaluable tool for characterizing muscle-type AChRs. Although it was originally inferred that αBgt binds to neuronal AChRs, later works made it clear that the αBgt receptors and neuronal acetylcholine receptors are not equivalent [see e.g. Carbonetto et al., Proc. Natl. Acad Sci USA 75, 2 (1978) on the non-equivalence of α-Bungarotoxin receptors and acetylcholine receptors in chick sympathetic neurons]. Since αBgt does not bind to neuronal nicotinic AChRs, it is not a useful probe for structural studies. More recently, monoclonal antibodies (mAbs) have proven extremely useful in studying neuronal AChRs. Immunoaffinity-purified neuronal AChRs were found to consist of only two kinds of subunits. The larger subunit was identified as the ACh-binding subunit by nicotine-blockable 4-(N-maleimido)benzyltri[ 3 H]-methylammonium iodide (MBTA) labeling after reduction, suggesting that it contains cysteines homologous to cysteines 192,193 of the muscle-type Torpedo AChR α subunits. The lower molecular weight subunit is often called the β subunit, but, more informatively, is also referred to as the structural subunit. The subunit stoichiometry is uncertain, but there are indications that it may be x 2 y 2 (x and y standing for the ACh-binding and structural subunits, respectively). These subunits exhibit sequence homologies which indicate that they belong to the same gene family as the subunits of muscle-type nicotinic AChRs. There appear to be several subtypes of these AChRs, including at least four kinds of ACh-binding subunits and two kinds of structural subunits. Some different subtypes may use the same structural subunit and differ in which ACh-binding subunit they use. Schoepfer et al., Molecular Biology of Neuroreceptors and Ion Channels, NATO-ASI Series, H vol. 32, pp. 37-53 (1989), A. Maelicke (Ed.), Springer-Verlag, Heidelberg, and the references cited therein provide a comparison of the structures of muscle and neuronal nicotinic AChRs. Further details of the character of neuronal nicotinic AChRs from different sources (chicken brain, rat, bovine, human, etc.) and of the distribution of the two types of subunits can be found, for example, in Whiting and Lindstrom, J. Neurosci. 8(9), 3395 (1988), and Wada et al., J. Comp. Neurol. 284, 314 (1989).
Some receptors for glycine and γ-aminobutyric acid, such as the strychnine-binding glycine receptor of the spinal cord and the brain γ-aminobutyric acid A (GABA A ), are ligand-gated anion channels which appear to be more distant members of the same receptor superfamily which includes nicotinic receptors and may include other ligand-gated ion channels such as some receptors for glutamate and serotonin. Barnard et al., Trends Neurosci. 10, 502 (1987) compare the primary structures of the brain GABA A receptor, one of the subunits of the spinal cord glycine receptor and those of muscle-type and neuronal nicotinic AChRs.
Other neurotransmitter receptors whose subunit cDNAs have been cloned, are characterized as receptors without intrinsic ion channels. These receptors act through a GTP-binding protein and various enzymes to produce second messengers. All these receptors have a single subunit with sequence homology to rhodopsin. Typical representatives of this group are muscarinic AChRs and adrenergic receptors. Muscarinic AChRs are distinguished by their differential sensitivity to the alkaloid compound muscarine, and regulate a broad range of physiological and biochemical activities throughout the central and autonomic nervous systems via the activation of guanine nucleotide binding (G) proteins. A good summary of the recent knowledge about the structural and biochemical diversity of muscarinic AChRs is provided by Peralta et al., TIPS-February supplement, 6 (1988). Subtype-specific agonist and antagonist binding characteristics of chimeric β 1 and β 2 -adrenergic receptors are disclosed by Frielle et al., Proc. Natl. Acad. Sci. USA 85, 9494 (1988).
As mentioned before, the neuronal AChRs exhibit high affinity for nicotine and other cholinergic agonists, but do not bind βBgt. Binding studies using the technique of autoradiography to produce detailed maps of [ 3 H]nicotine, [ 3 H]ACh and [ 125 I]αBgt labeling in near-adjacent sections of rat brain have revealed that whereas [ 3 H]nicotine and [ 3 H]ACh bind with strikingly similar pattern, there is remarkably little overlap with [ 125 I]αBgt labeling [Clarke et al., Journal Neurosci. 5, 1307 (1985)]. Based upon their experiments, that were in excellent agreement with previous works on αBgt binding in rodent brain, Clarke et al. concluded that αBgt may label a new kind of nicotinic receptors, that is clearly different from nicotinic AChRs. These receptors are usually referred to in the literature as neuronal αBgt binding proteins (αBgtBPs). Their concentration throughout the vertebrate brain is considerably higher than that of neuronal AChRs. A number of laboratories have documented the existence of αBgtBPs in sympathetic ganglion membranes and membrane fragments derived from vertebrate brain. Since the ability of cholinergic ligands to effect receptor function remained unknown and αBgt was found to have no effect on agonist-induced activation of acetylcholine receptors in these tissues, the identity of the toxin-binding component was entirely uncertain. The binding of αBgt to a clonal rat sympathetic nerve cell line was described by Patrick, J. and Stallcup, W., J. Biol Chem. 252, 8629 (1977). The binding was found to be saturable and was inhibited by a variety a cholinergic agonists and antagonists. In assays determining the binding constants for various cholinergic ligands no correlation was found between their ability to affect cholinergic function and to inhibit binding of αBgt. It was found that the site at which cholinergic ligands affect AChR function is different from the site at which cholinergic ligands inhibit αBgt binding. The authors concluded that the αBgt binding component is probably a single molecular species of an integral membrane protein which is different from the functional neuronal nicotinic AChR.
Carbonetto et al., Supra delivered evidence that the αBgt receptors in chick sympathetic neurons are not neuronal AChRs. Similar results were reported by Smith et al., J. Neurosci. 3, 2395 (1983) and Jacob et al., J. Neurosci. 3, 260 (1983) on chick ciliary ganglion neurons. The major findings in these articles are that neuronal levels of ACh sensitivity do not correlate with αBgt binding sites, and in the case of chick ciliary ganglion cells the αBgtBPs, unlike neuronal nicotinic acetylcholine receptors, are not located at synapses. Although Smith et al. have ruled out some trivial reasons for the lack of correlation between ACh sensitivity and αBgt binding, they or Jacob et al., Supra provide no explanation of the function of the αBgt binding site.
Conti-Tronconi et al., Proc. Natl. Acad. Sci. USA 82 (1985) purified αBgt-binding proteins from chick optic lobe and brain under conditions that were designed to minimize proteolysis. Five different peptides with molecular weights ranging between about 48,000 and about 72,000 were separated by gel electrophoresis and submitted to amino-terminal amino acid sequencing. The amino-terminal amino acid sequence of the 48,000 molecular weight subunit was found to be highly homologous to the sequences of known α subunits of peripheral AChRs from Torpedo electroplax, Electrophorus electroplax and muscle, and calf muscle. Amino-terminal amino acid sequence analysis of the other isolated protein fragments did not yield any signal above the high background consistently present, indicating that these fragments probably had blocked amino termini. Although there are some indications that the protein fragments not sequenced may be part of the same receptor, the subunit structure of brain αBgtBPs has not been established. Conti-Tronconi et al., Supra add to the confusion concerning the terminology, identity, and function of vertebrate αBgt binding proteins by concluding that brain αBgtBPs are nicotinic AChRs.
Whiting, P. and Lindstrom, J., Proc. Natl. Acad. Sci. USA 84, 595 (1987) report the purification of an αBgtBP from rat brain and the identification of four kinds of subunits. The four polypeptides separated by affinity-purification of the αBgtBP were similar in their apparent molecular weights to the α, β, γ and δ subunits of muscle-type nicotinic AChRs. In the absence of antibody probes for the toxin binding protein, the authors could not unequivocally demonstrate that each of the four polypeptides were true constituents of the same macromolecule.
Like muscle and neuronal AChRs, αBgtBPs can be affinity labeled with MBTA after reduction with dithiothreitol (DTT). In chicken brain this labels a subunit of apparent molecular weight of 45,000. This suggests that, as in nicotinic AChRs, there is a readily reducible disulfide bond near the ACh binding site. The ACh-binding subunits of all nicotinic AChRs characterized to date exhibit a pair of cysteines homologous to the disulfide-bound pair at α192,193 in muscle-type AChR α subunits which are known to be affinity labeled by MBTA.
Norman et al., Proc. Natl. Acad. Sci. USA 79, 1321 (1982) report the isolation of the αBgtBP from chick optic lobe as a pure glycoprotein and compare this protein with the αBgt-binding component isolated from the rest of the chick brain. The authors conclude that the αBgtBP from chick optic lobe and the αBgtBP from the rest of the brain appear similar or identical by a series of criteria and are both related to peripheral AChRs. For further information see, for example: Kao et al., J. Biol. Chem. 259, 11662 (1984); Kao et al., J. Biol. Chem. 261, 8085 (1986); Whiting, P. and Lindstrom, J., FEBS Lett. 213(1), 55 (1987); and Whiting et al., FEBS Lett. 219(2), 459 (1987).
The selected literature references cited hereinabove illustrate the controversial nature of our present knowledge about αBgtBPs. The following main observations have been made so far:
Vertebrate (avian and mammalian) brains contain both nicotinic AChRs which have high affinity for nicotine and acetylcholine but not for αBgt, and distinct αBgt-binding sites. There are more αBgtBPs than neuronal AChRs.
In some cases (chick ciliary ganglion cells, chick sympathetic ganglion cells, rat PC12 pheochromocytoma cells), αBgtBPs appear to be made by cells which also produce neuronal nicotinic AChRs, but these αBgtBPs do not appear to function as ACh-gated cation channels.
In the case of chick ciliary ganglion cells, the αBgtBPs are not located at synapses.
There are some claims of vertebrate neuronal AChRs whose function is blocked by αBgt, but so far they are not supported by conclusive evidence.
The αBgt-binding proteins from brains of chicks, and rats (similarly to muscle-type AChRs, and neuronal AChRs) can be affinity labeled with BAC and MBTA, after reduction with DTT. This suggests that amino acid residues homologous to Cys α192-193 of electric organ and muscle AChRs may have been conserved in the members of what appears to be an extended gene family consisting of muscle-type AChRs, neuronal AChR subtypes, and neuronal αBgtBPs.
The partial N-terminal amino acid sequence of one αBgtBP subunit of apparent molecular weight of 48,000 (Conti-Tronconi, et al., Supra) from chicken brain exhibits sequence homology with AChR subunits. This, along with pharmacological properties, is another indication that muscle-type and neuronal nicotinic AChRs and αBgtBPs are probably members of the same gene superfamily.
It is certain that neuronal αBgtBPs are functionally, structurally, immunologically, histologically, and pharmacologically distinct from functional vertebrate AChRs which do not bind αBgt.
However, the function of the αBgt-binding sites remains obscure. There is a large body of evidence indicating that the αBgtBPs which have been most carefully studied are not ACh-gated cation channels. Although there are indications that they may have several subunits, the subunit structure of αBgtBPs is unclear. The only information available in the art concerning the sequence of αBgtBP subunits, is a short N-terminal amino acid sequence of a polypeptide of the αBgtBP from chicken brain reported by Conti-Tronconi, et al., Supra.
SUMMARY OF THE INVENTION
Starting with an oligonucleotide probe based on the N-terminal amino acid sequence reported by Conti-Tronconi et al., Supra for an αBgtBP subunit from chick brain, cDNA clones have been identified which code for a protein of 502 amino acids, having a deduced molecular weight of 56,950 (with a mature peptide lacking a signal sequence of 54,550) that has been identified as a subunit of a brain αBgtBP. In one aspect, the present invention relates to the above cDNAs and to the encoded subunit, hereinafter termed the αBgtBP α1 subunit. Details of the clone names and methods involved are reported in the Examples, in particular in the Experimental Procedures section.
Using fragments of the cDNA αBgtBPα1 as probe, another closely related homologue cDNA clone was isolated from a chick brain cDNA library, encoding a 511 amino acid-containing protein with a molecular weight of 58,710 (putative mature peptide: 55,230). The encoded protein was identified as another αBgtBP subunit. In another aspect, the present invention relates to the above cDNA and to the encoded second subunit, hereinafter termed αBgtBPα2 subunit. Details of the clone names and methods are reported in the Examples, in particular in the Experimental Procedures section.
In another aspect, the present invention relates to the production of the α1 and α2 αBgtBP subunit proteins and fragments thereof by methods of recombinant DNA technology.
In a further aspect, the present invention concerns the use of cDNA clones encoding the neuronal αBgtBP α1 and α2 subunits as probes that can, for example, identify further neuronal αBgtBP subunits in chickens and other species such as humans.
In a still further aspect, the invention relates to the use of neuronal αBgtBP and, in particular, the α1 and α2 subunits as diagnostic tools in the screening of cholinergic and other drugs that may affect the ligand binding, ion channel or other activity of intact neuronal αBgtBP subtypes.
The present invention is directed to the above aspects and all associated methods and means for accomplishing such. For example, the invention includes the technology requisite to screening genomic cDNA libraries, nucleotide sequence determination, the preparation of antisera to αBgtBP, etc. The invention further includes the use of an expression system suitable for preparing substantial amounts of αBgtBP subunit peptides for use as immunogens for preparing antisera and monoclonal antibodies to native αBgtBP, to permit affinity purification of subtypes, and their histological location.
The present invention provides critical groundwork for practical applications and future studies of neuronal αBgtBPs.
For the first time, the sequences of αBgtBP subunits have been determined, proving that this protein is a member of the AChR gene family and that subtypes exist.
The cDNA clones of the present invention, probably in combination with other related cDNA clones for further αBgtBP structural subunits, should allow the recombinant production of intact αBgtBP in suitable recombinant expression systems. This will permit evaluation of the function of this protein, e.g. whether it will function as a ligand-gated ion channel after appropriate post-translational modifications or in the presence of appropriate cofactors, and permit determination of the endogenous ligand (which may not be ACh) for this αBgtBP. Expression systems will also permit assay of the effects of cholinergic and other drugs on ligand binding and ion channel or other activity of intact αBgtBP subtypes.
Furthermore, the cDNA sequences of the present invention provide probes for identifying the remaining subunits of neuronal αBgtBPs from chicken brain but also from other species including human. These nucleic acid probes can also provide peptides useful for making antibody probes. Human cDNA probes may ultimately prove useful for identifying altered sequences in genetic diseases.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows the deduced N-terminal amino acid sequences of the α1 and α2 αBgtBP subunits of the present invention, in alignment with the chemically determined N-terminal amino acid sequence published by Conti-Tronconi, et al., Supra. cDNA-deduced amino acids identical with the published protein sequence are marked by *.
FIGS. 1B and 1C illustrate the αBgtBP α1 and α2 subunits, in comparison with ACh-binding subunits of chicken AChRs.
FIGS. 2A and 2B show the nucleotide sequence and the deduced amino acid sequence of the α1 subunit. The mature protein starts at position +1. The underlined sequence was also confirmed by polymerase chain reaction (PCR) as described in the Examples.
FIGS. 3A and 3B illustrate the nucleotide sequence and the deduced amino acid sequence of the α2 subunit. The putative mature protein starts at position +1.
FIG. 4 summarizes the identification of the cDNA clones which led to the deduced sequences of the α1 and α2 subunits of αBgtBP.
FIG. 5 shows that antibodies to bacterially expressed fragments of proteins encoded by fragments of cDNAs for αBgtBP α1 and α2 subunits, in fact, bind to authentic αBgtBP in detergent extracts of chicken brains, and further shows that the αBgtBP α1 subunit is present in a subtype of αBgtBP, which accounts for about 75% of the total, whereas the αBgtBP α2 subunit is present in a subtype which accounts for less than 20% of the total αBgtBP in brain extracts tested.
DETAILED DESCRIPTION OF THE INVENTION
1. Definitions
The amino acids, which occur in the various amino acid sequences referred to in the specification have their usual, three- and one-letter abbreviations, routinely used in the art, i.e.:
______________________________________Amino Acid Abbreviation______________________________________L-Alanine Ala AL-Arginine Arg RL-Asparagine Asn NL-Aspartic acid Asp DL-Cysteine Cys CL-Glutamine Gln QL-Glutamic Acid Glu EL-Glycine Gly GL-Histidine His HL-Isoleucine Ile IL-Leucine Leu LL-Lysine Lys KL-Methionine Met ML-Phenylalanine Phe FL-Proline Pro PL-Serine Ser SL-Threonine Thr TL-Tryptophan Trp WL-Tyrosine Tyr YL-Valine Val V______________________________________
As used herein, "AChR" stands for acetylcholine receptor, including muscle-type and neuronal nicotinic acetylcholine receptors, and "ACh" for acetylcholine.
As used herein, "αBgt" stands for α-Bungarotoxin, and αBgtBP for α-Bungarotoxin-binding proteins, in particular neuronal α-Bungarotoxin-binding proteins.
The term "mAbs" as used in the specification and claims, stands for monoclonal antibodies.
The term "expression vector" includes vectors capable of expressing DNA sequences contained therein, where such sequences are in operational association with other sequences capable of effecting their expression, i.e. promoter sequences. "Operatively harboring" means that the DNA sequences present in the expression vector work for their intended purpose. In general, expression vectors usually used in recombinant DNA technology are often in the form of "plasmids", i.e. circular, double stranded DNA loops which in their vector form, are not bound to the chromosome. In the present specification the terms "vector" and "plasmid" are used interchangeably. However, the invention is intended to include other forms of expression vectors as well, which function equivalently.
2. Deposits
Plasmid DNAs containing cDNA inserts encoding the α1 and α2 subunits of αBgtBP were deposited at the American Type Culture Collection (Rockville, Md.) under deposition numbers shown below. As explained in Examples and Experimental Procedures and shown in FIG. 4, clones pCh34-1 and pCh29-3 together encode αBgtBPα1, whereas the entire coding sequence of αBgtBPα2 is included within clone pCh31-1.
______________________________________Clone Encodes ATCC No.______________________________________Plasmid DNA, pCh29-3 αBgtBPα1 40641 N-terminal partPlasmid DNA, pCh34-1 αBgtBPα1 40639 C-terminal partPlasmid DNA, pCh31-1 αBgtBPα2 40640______________________________________
Said deposits were made, and accepted by ATCC, under the terms of the Budapest Treaty on the International Recognition of the Deposits of Microorganisms for Purposes of Patent Procedures and the regulations promulgated under said Treaty. Samples of said deposits will be available, in accordance with said Treaty and Regulations, to industrial property offices and other persons and entities legally entitled to receive them under the patent laws and regulations of the United States of America and any other nation or international organization in which the present application, or an application claiming priority of the present application, is filed. All restrictions on the public availability of samples of said deposits will be irrevocably removed, at the latest upon issuance of a United States patent on this application.
The foregoing description and the experimental details set forth in the following Example disclose a methodology that was initially employed by the present researchers in identifying and isolating particular neuronal αBgtBP subunits. Anyone with ordinary skill in the art will recognize that once this information, including the cDNA and protein sequences, and characterization and use of these receptor subunits, is available, it is not necessary to repeat the technical details disclosed herein to reproduce the present invention. Instead, in their endeavors to reproduce this work, they may choose convenient and reliable alternative methods that are known in the art. For example, they may synthesize the underlying DNA sequences for deployment within similar or other suitable, operative expression vehicles. The sequences herein may be used to create probes (e.g. as illustrated in the Example), preferably from regions at both the N- and the C-termini, to screen genomic libraries for further cDNA fragments. Furthermore, the sequence information herein may be used in cross-hybridization procedures to isolate, characterize and deploy DNA encoding αBgtBPs or their subunits from various species, including human.
Thus, in addition to supplying details of the procedures actually employed, the present disclosure serves to enable reproduction of the disclosed specific receptor subunits and other, related subunits and/or receptors, using means within the skill of the art having benefit of the present disclosure. All of such means are included within the enablement and scope of the present invention.
3. Example
A. Cloning of αBgtBP cDNAs
Using a 47-mer oligonucleotide of sequence 5'GGGTTGTAGTTCTT C G AG G C AGCTGCTTGTA G C AGCTTGGTCTGGAACTG 3' designed on the previously chemically determined N-terminal protein sequence of a subunit of a toxin-affinity-purified αBgtBP (Conti-Tronconi et al., Supra), clone pCh29-1 has been isolated from a chick brain E17 cDNA library [Schoepfer et al., Neuron 1, 241 (1988)]. The deduced amino acid sequence in one reading frame was found to be identical to the chemically determined protein sequence in 20 of 22 residues, as shown in FIG. 1A. (In the Conti-Tronconi sequence the residues marked by "X" were not identified.) The same reading frame codes further 5' for a peptide with the characteristics of a leader peptide and has an open reading frame further 3' (FIGS. 2A and 2B). This open reading frame codes for amino acids (aa)-22 through 179 in FIGS. 2A and 2B. Thus, a partial cDNA clone coding for a subunit of a brain αBgtBP has been identified. For further characterization clone Ch29-3 was used. pCh29-3 is a subclone of pCh29-1, and contains all the sequences coding for the N-terminal fragment of the αBgtBPα1 subunit found in pCh29-1. pCh29-3 lacks further 5', untranslated sequences found in pCh29-1 which were only partially characterized. Since this clone is fully characterized, and was used in further experiments, pCh29-3 was deposited with ATCC. Another cDNA clone (pCh34-1) which encodes the remainder of the αBgtBPα1 sequences was identified later, as described in Experimental Procedures and depicted in FIG. 4. The protein fragment encoded by pCh29-3 together with the fragment encoded by pCh34-1 (then termed pCh29/34) are fragments of a protein of 502 aa with a deduced molecular weight of M r =56,950 (mature peptide M r =54,550).
The protein has the general features of a subunit of a ligand-gated ion channel (FIGS. 1B and 1C): four hydrophobic segments termed M1-4, with M1-3 found very close together; a pair of cysteines spaced by 13 aa (128 and 142 in FIG. 1B); and some amino acids conserved throughout ligand-gated cation and anion channels. FIGS. 1B and 1C show only the alignment with brain AChR ACh-binding subunits. Because the pCh2934-encoded sequence shows the pair of adjacent cysteines characteristic of ACh-binding subunits, which have conventionally been termed "α," this subunit was termed the αBgtBP α1 subunit.
Another cDNA clone (pCh31-1) was isolated by low-stringency screening with fragments of Ch29-1. This encodes a complete sequence for the αBgtBP α2 subunit, and fragments corresponding to the C-terminal part were used to identify the cDNA pCh34-1, which encodes the C-terminal part of αBgtBP α1 subunit, as summarized in FIG. 4, and detailed in Experimental Procedures. Clone pCh31-1 for the αBgtBP α2 subunit encodes a 511 aa protein with a molecular weight of M r =58,710 (putative mature peptide M r =55,230). The sequence has the same general features as the α1 subunit. Without signal peptides, the α1 and α2 subunits are 62% identical overall (FIGS. 1B and 1C); most of the divergent amino acids are found in the putative cytoplasmic loop between aa 329 and 414, which shows basically no conservation except for stretches of five and three aa. Interestingly, α1 and α2 also differ significantly in their first 23 amino acids. In the N-terminal amino acid sequence of α2, there are only 13 amino acids out of 22 that are identical to the Conti-Tronconi sequence (FIG. 1A).
The nucleotide sequence of clone pCh31-1 together with the deduced amino acid sequence of the α2 subunit is illustrated in FIGS. 3A and 3B. The putative mature protein starts at position +1.
B. Subunit-Specific Antisera Tests
To critically test whether these cDNAs coded for subunits of authentic αBgtBP, cDNA sequences corresponding to amino acids 327 to 412 of αBgtBPα1, and 293 to 435 of αBgtBPα2 were expressed in bacteria, antisera were raised to unique peptide sequences encoded by these cDNAs, and the antisera obtained were tested for their ability to recognize native αBgtBP in detergent extracts of chicken brains.
Rats immunized with protein Ch31-5, a recombinant protein corresponding to the putative large cytoplasmic loop between M3 and M4 of the αBgtBP α2 subunit, developed high titer antisera against genuine chicken brain αBgtBP after a few weeks. Subsequently, mAbs were isolated which could bind to native αBgtBP. After sequencing the αBgtBP α1 subunit, we realized that protein Ch31-5 (α2 subunit) might have some epitopes in common with the αBgtBP α1 subunit. Therefore, mAbs raised against protein Ch31-5 were also tested on Western blots against protein Ch31-6, a shorter fragment of the putative cytoplasmic loop unique to the αBgtBP α2 subunit. mAb 308 and other mAbs not shown here bind to protein Ch31-6, thus they are specific for the αBgtBP α2 subunit, and possibly as yet unidentified subunits.
Polyclonal antisera against the unique cytoplasmic loop of the αBgtBP α1 subunit (pCh34-2) also recognized genuine brain αBgtBP.
FIG. 5 shows immunoprecipitation of αBgtBP from brain extracts by antibodies to native αBgtBP and to fragments of α1 and α2 subunits of αBgtBP expressed in bacteria. mAb306 was raised to native affinity purified αBgtBP and binds to 100% of αBgtBP detectable in extracts of chicken brains. The subunit to which it binds is not known because its epitope is dependent on the native conformation of αBgtBP. Antisera to the bacterially expressed fragment of αBgtBP α1 subunit binds to a major subtype of αBgtBP which accounts for about 75% of the total. mAb 308 to the bacterially expressed fragment of αBgtBP α2 subunit binds to a minor subtype of αBgtBP which accounts for less than 20% of the total.
C. Experimental Procedures
a. Cloning of αBgtBP Clones
Cloning was performed using standard procedures of recombinant DNA technology [see e.g. Maniatis et al., Molecular Cloning, A Laboratory Manual, Cold Spring Harbor: Cold Spring Harbor Laboratory (1982); and Berger, S. L. and Kimmel, A. R. (Eds.): Guide to molecular cloning techniques, Meth. Enzymol. 152 (1987)].
A cDNA library (Schoepfer et al., Neuron 1, 241 (1988) from embryonic day 18 (E18) chicken brains was screened with the 47-mer oligonucleotide designed on the chemically determined N-terminal protein sequence of one subunit of toxin-purified chicken brain αBgtBP (Conti-Tronconi et al., Supra), basically following codon usage frequencies.
The procedures by which cDNAs for the α1 and α2 subunits of αBgtBP were identified is are shown in FIG. 4. Using the oligonucleotide based on the N-terminal amino acid sequence of an αBgtBP subunit, a clone termed pCh29-1 was identified. Due to the properties of the cDNA library used, this clone ends at an EcoRI site in the middle of the sequence encoding α1 subunit. This clone also contains extensive 5' untranslated sequences. Thus, a subclone, pCh29-3, was made which eliminates these untranslated sequences, but retains the sequences encoding the N-terminal part of the α1 subunit. Using this sequence as a probe, a cDNA, pCh31-1, was identified which encoded the entire sequence of α2. This provided a probe for identifying a clone for the C-terminal part of α1, pCh34-1. In order to show that the coding sequences of pCh29-3 and pCh34-1 were actually part of a single mRNA which was cleaved at an EcoRI site during cloning, a fresh avian mRNA preparation was used to produce cDNA, and then the polymerase chain reaction (PCR) primed with terminal oligonucleotides from pCh29-3 and pCh34-1 was used to amplify a sequence which proved to overlap the two clones and demonstrate that they derive from a single mRNA.
Stringency conditions were 30% formamide, 5×SSPE (1×SSPE is 0.18M NaCl, 0.01M NaPO 4 , pH 7.4, and 1 mM EDTA) at 42° C. for hybridization, followed by final washings at 55° C., 1×SSPE (clone pCh29-1 was identified in this way). Using pCh29-1 or a fragment thereof (i.e. pCh29-3) as a probe, pCh31-1 was isolated, and subsequently, using pCh31-1 fragments as probes, pCh34-1 was isolated. The nucleotide sequences were completely determined in both strands. By deduced amino acid sequence homology to pCh31-1 and by common EcoRI sites (nucleotides 533-539, FIG. 2A) it is likely that pCh29-3 codes for the N-terminal and pCh34-1 for the C-terminal part of the α1 subunit. As apparently all cDNA EcoRI sites in this library were cleaved, the contiguousness of pCh29-3 and pCh34-1 was demonstrated by the polymerase chain reaction (PCR) technique [White et al., Trends Genetics 5, 185 (1989)]. Ca 300 ng E17 chicken brain first and second strand cDNA was subjected to 35 cycles (1 minute, 92.5° C.; 2 minutes, 55° C.; 1 minute 30 second, 72° C. on an Ericomp Temperature cycler) using Taq polymerase (Perkin Elmer) with the supplier's recommended buffer. The 5' primer (24-mer) sequence was derived from pCh29-3, the 3' primer (24-mer) sequence from pCh34-1. Plasmids containing the specific reaction product were sequenced (underlined in FIGS. 2A and 2B), proving to be identical between the primers used to pCh29-3 and pCh34-1 spliced together at the EcoRI site.
b. Antisera to αBgtBP
Fragments of pCh31-1 and pCh34-1 were subcloned into a T7 promoter-based bacterial expression system described by Rosenberg et al., Gene 56, 125 (1987). At least the cloning sites were sequenced for all constructs. The deduced protein sequences of the recombinant proteins are:
protein Ch34-2 (encoding a small, unique sequence of αBgtBPα1, see FIG. 1C):
MASMTGGQQMGRDPSSRSAGEDKVRPACQHKQRRCSLSSMEMNTVSGQQCSNGNMLY IGFRGLDGVHCTPTTDSGVICGRMTCSPTEEENLLHSGHPSEGDpDLANSKLDPAAN KARKEAELAAATAEQ
protein Ch31-5 (encoding the large putative cytoplasmic domain of αBgtBPα2, see FIG. 1C):
MASMTGGQQMGRIKLRIPWYQLQFHHHDPQAGKMPRWVRVILLNWCAWFLRMKKPGE NIKPLSCKYSYPKHHPSLKNTEMNVLPGHQPSNGNMIYSYHTMENPCCPQNNDLGSK SGKITCPLSEDNEHVQKKALMDTIPVIVKILEEVQFIAMRFRKQDEGEEIRLLTKPE RKLSWLLPPLSNN
protein Ch31-6 (encoding a smaller, unique sequence of αBgtBPα2, see FIG. 1C):
MASMTGGQQMGRDPSSRSAGENIKPLSCKYSYPKHHPSLKNTEMNVLPGHQPSNGNM IYSYHTMENPCCPQNNDLGSKSGKITCPLSEDNEHVQKKALMDTIPVIVNSKLDPAA NKARKEAELAAATAEQ
The underlined sequences are genuine to the deduced parent plasmid sequences, and the additional amino acids are vector-encoded.
Protein Ch34-2 was not found to form inclusion bodies. Therefore, SDS-PAGE-purified preparations were used for immunization of Lewis rats.
Protein Ch31-5 was obtained as inclusion bodies isolated by differential centrifugation. Impurities were successively extracted with 1M NaCl, 0.5% Triton X-100, and 3M KSCN, and then the inclusion bodies were solubilized in 8M urea. After removing the urea by dialysis, the partially soluble protein was more than 50% pure, as judged by Coomassie-stained SDS-PAGE. Lewis rats were immunized repeatedly with approximately 100 μg of protein in CFA.
Protein Ch31-6 was not purified for use as an immunogen, but only used as an antigen in Western blots, as described below.
c. Spleen Cell Fusion
The rat with the highest titer to protein Ch31-5 was immunized intraperitoneally, five days before the fusion, with 100 ng of protein Ch31-5 in PBS. On the day of the fusion the rat was killed and its spleen cells fused with Sp2/0 mouse myeloma cells using polyethylene glycol [Hochschwender et al., Production of rat×mouse hybridomas for the study of the nicotinic acetylcholine receptor, T. A. Springer, ed., New York: Plenum Publishing Corporation, pp. 223-238 (1985)]. Nine days after the fusion, the culture supernatants were screened in a radioimmunoassay for antibodies which bound 125 I-αBgt-labeled αBgtBP in extracts of embryonic chick brain (see procotol below). Positive cultures were cloned twice by limiting dilution and then expanded to large cultures. These five hybridomas were designated as mAbs 308-312. Culture media was collected, concentrated by ultrafiltration and ammonium sulfate precipitation, and dialyzed against PBS containing 10 mM NaN 3 .
d. Radioimmunoassay
Triton X-100 extracts of E18 chick brains were prepared according to the protocol described by Whiting and Lindstrom, Biochem 25, 2082 (1986). Antisera or mAb stock were diluted in PBS and incubated with 40 μl chick brain extracts containing 4 μl normal rat serum and 2 nM 125 I-αBgt (specific activity 2-5×10 17 cpm/mol) in a total volume of 100 μl. After overnight incubation at 5° C., 100 μl goat anti-rat immunoglobulin was added and incubated for another hour. PBS-Triton X-100 was added (1 ml) and the immune complexes pelleted and washed twice with PBS-Triton. 125 I-αBgt in the pellet was determined by ␣ counting. Nonspecific and background counts were determined using preimmune serum and were subtracted from all data. Maximum binding of 125 I-αBgt to αBgtBP in the extracts was determined by incubating 40 μl extract with 2 nM 125 I-αBgt in a total volume of 100 μl. After overnight incubation at 5° C., 4 ml 10 mM Tris, 0.05% Triton X-100, pH 7.5, was added and the mixture rapidly filtered through Whatman GF/B filters pretreated with 0.3% polyethylenimine [Bruns et al., Analyt. Biochem. 132, 74-81 (1983)]. The filters were washed three times with 4 ml of the same buffer and counted. Nonspecific binding was determined in the presence of 1 mM carbamylcholine. | An isolated DNA molecule encoding an α-bungarotoxin-binding protein (αBgtBP) subtype or a fragment of such α subunit is provided. The fragment of the α subunit is sufficiently homologous to specified DNA (FIG. 2A or FIG. 2B) so as to hybridize thereto under conditions of low stringency. Identification, characterization, isolation and sequencing of cDNA clones which encode two neuronal αBgtBP subunits, α1 and α2, is made possible. Such clones may be used as probes to identify further neuronal αBgtBP subunits, or as diagnostic tools to screen cholinergic agents and other drugs that may affect ligand binding, ion channel or other activity of intact neuronal αBgtBP subtypes. | 2 |
BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
This invention relates to a method and apparatus for boresighting such components as weapons systems and avionics equipment aboard fixed-wing and rotary-wing aircraft as well as tanks and other vehicles to thereby insure that a weapons delivery point coincides with its aimpoint. Through the use of optical metrology, the various components are boresighted to maintain alignment relative to the aircraft boresight reference line.
Specifically, this optical metrology system accomplishes boresighting through the transfer of a fixed reference line in yaw, pitch, and roll from a measurement reference line on an aircraft or other vehicle to various points including sighting stations, sensors and weapon stations.
For example, it is necessary that various modules on both rotary and fixed-wing aircraft maintain correct positions within 30 arc seconds or less. Through use of the boresighting system of the present invention, departures from the prescribed position can be measured and corresponding corrections effected.
Typical modules include a heading and attitude reference system, gun, stabilized sight unit, night vision unit, doppler radar, air data sensor, missiles, head-up display, forward looking infrared and laser spot tracker.
PRIOR ART
Alignment devices have been employed in the past to verify boresight alignment and to measure boresight error between a reference line of sight and the sighting means of the vehicle and a weapon on military aircraft and other vehicles.
One such system is that of U.S. Pat. No. 4,762,411 which shows a boresight alignment verification device comprising a portable cart spaced apart from the aircraft which carries the sights and weapons to be boresighted and employing a collimated light source and an extendable periscope which directs light to an optical reference fixture mounted at a line of sight on the aircraft. The reflected light is matched on a matrix camera against a beam-split portion of the projected light. This arrangement has the disadvantage of relative movement between the spaced-apart verification means during the frequently lengthy calibration period and corresponding repositioning, in contrast to applicant's system in which the verification means is attached to the aircraft and is not relatively movable thereto.
U.S. Pat. No. 4,191,471 shows an aircraft armament alignment arrangement employing a jig which is temporarily fastened to the aircraft. A collimated, incoherent light source is attached to the aircraft at a reference surface which defines an aircraft datum line. A collimator fastened to the jig carries a translucent screen with grid markings on which the image of the light source is visible. The jig is moved relative to the aircraft until the image is centered and is there fixed. Thus, the jig becomes an intermediate element for carrying directionality and alignment information to a weapon bore and to a sight. The collimated light source is next attached to produce a beam parallel to the bore of a gun pod and the gun pod adjusted so as to center its light beam on the screen of the repositioned collimator. The collimated light source is then moved to a socket on the jig and its light beam directed to an optical sight. The latter is then adjusted until its line of sight is parallel to the axis of the collimated light source. Factors detracting from the potential accuracy of this system are errors resulting from the use of an intermediate element and the repositioning of the light source and the collimator.
SUMMARY OF THE INVENTION
An object of this invention is to provide a means for boresighting a number of modules on an aircraft through employment of optical metrology principles.
This is accomplished, in its simpliest form, through use of a laser, a position sensitive sensor receiving light from said laser and one or more light deviating means positioned between the laser and the detector.
The apparatus consists of one or more optical cubes, a projector, a deviator section, and a sensor or receiver. The projector emits a collimated beam of laser light perpendicular to one mirrored face of the cube. The deviator is a form of periscope or retroreflector using mirrors or prisms for altering the direction or position of light while insuring that the displaced beam remains parallel to the incident beam. The sensor measures any difference in direction between an incoming beam (from the cube and the projector and via the deviator) and the direction perpendicular to a second optical cube. The projector is a retroflective catadioptric collimator shown here as a doublet, carrying on its axis a single mode optical fiber which terminates at the nodal point of the lens. The fiber directs light to the mirrored face of an optical cube, spaced a distance equal to one-half the focal length of the lens, which is then redirected to the lens. The fiber receives light from a solid state laser, which may have any convenient wavelength; for the present invention a wavelength of 670 nm is preferred.
The receiver is of a form similar to the projector, comprising a lens of doublet or other construction, and the mirrored face of an optical cube with a position sensitive detector or sensor located at the nodal point of the lens. The detector may be a lateral effect cell, a quadrant detector or a CCD camera.
The optical deviator may be of the zero deviation (rhomboid) or the 180 degree deviation type. In the former the reflectors are spaced-apart flat mirrors with their surfaces parallel. In the 180 degree deviation one flat mirror and one roof reflector or roof prism are used.
Deviators may be combined, or articulated, to provide a variable length between the point of light input and the point of light output. These cascaded or articulated deviators may be of either the zero deviator or 180 degree deviation type.
In use, the output of a projector is focused on the sensor in the receiver, with or without intervening deviators. Departure from an aligned condition results in an analog, digital or video representative which indicates the degree and direction of such departure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows, in cross-sectional view, an optical cube and projector for producing a collimated beam of laser light.
FIG. 2 shows the projector of FIG. 1 in front elevational view.
FIG. 3 shows, in detail the means for attaching the projector to the cube.
FIG. 4 shows the projector attached to the cube.
FIG. 5 shows, in partial cross-sectional view, an optical cube and a sensor for receiving light from a projector.
FIG. 6 shows the sensor of FIG. 5 attached to a cube.
FIG. 7 shows, in partial cross-section, one type of deviator for delivering light from a projector to a sensor.
FIG. 8 shows, in partial cross section another type of deviator.
FIG. 9 shows a typical arrangement employing a projector, a sensor and two deviators.
FIG. 10 shows a pair of deviators coupled together to form an articulated variable length structure.
FIG. 11 shows the detailed structure of a zero degree deviator.
FIG. 12 shows the system set up to perform a full boresighting task.
FIG. 13 is a block diagram for the pitch and yaw read-out unit.
FIG. 14 is a block diagram showing the transmitter and receiver arrangement for display of pitch, yaw and roll.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows in vertical cross section a typical transmitter 10 which cooperates with the mirrored face 12 of an optical cube 14. Transmitter 10 consists of a body 16 which carries within a cylindrical opening at one end a collimating lens 18, shown here as a doublet, which is provided with an axial hole. Into the hole is cemented or otherwise coaxially attached a single mode optical fiber 20 one end of which terminates at the second nodal point 22 of the lens. The other end of the fiber receives light from a laser diode 24 located in a cavity in the body as shown in FIG. 2. Electronics 26 for the laser are housed in a second cavity in the body. In case the very tight collimation provided by a single mode fiber illuminated by a laser is not needed (as with less extreme distances) a multi-mode communications fiber (core diameter on the order of 50 micrometers) illuminated with a non-coherent source (a light emitting diode for example) can be used.
Location of the end of the fiber at the nodal point insures that the direction of the projected beam remains perpendicular to the mirrored surface 12 despite any tilting of the transmitter. Embedding the light source for the collimator, i.e., the fiber, in the lens insures that the direction of the collimated light is not influenced by any movement of the transmitter whatsoever.
As best seen in FIG. 1, light emitted from the end of the fiber is reflected by mirrored surface 12 of cube 14 back to lens 18 from which it projects as a beam of collimated light 28.
FIGS. 3 and 4 show a long view A--A of FIG. 1 and on an enlarged scale, one arrangement for attaching transmitter 10 to the optical cube. A flat steel washer 30 is cemented to a mirrored face of cube 10 and acts as one surface of a magnetic catch. An annular magnet 32 acting as the second face of the magnetic catch is carried on several extension springs 34 carried within an annular cover 36 fastened to body 16. When that end of body 16 is held against the cube, magnet 34 fastens itself to washer 30, and with the aid of springs 34 forces the end of body 16 into contact with the cube. Other arrangements using hooks, straps or clamps may be used as preferred.
FIGS. 5 and 6 show in partial sectional and front elevational views, respectively, a receiving sensor for cepting collimated light from the transmitter of FIGS. 1 to 4. The sensor housing, or receiver, 40, comprises a body member 42 which carries at one end a collimating lens 44 in an arrangement analagous to that of transmitter 10. Lens 44 is provided with an axial hole 46 into which is fitted, coaxially with lens 44, a position sensor 48, the active surface 50 of which is located at the nodal point of lens 44. Mirrored face 12 of optical cube 14, to which body 44 is fastened in a manner similar to that of FIGS. 1 to 4, cooperates with lens 44 to focus incoming collimated light 51 onto the surface of the position sensor. The position sensor may be a lateral effect cell, a quad cell, a charge coupled camera (CCD) or similar device. The electronics 52 for the position sensor are held on one side of the body. Location of the sensor at the nodal point of the lens insures the integrity of its optical axis in a manner similar to that of the fiber and lens arrangement of the transmitter.
FIG. 7 shows, diagrammatically, a zero degree, or rhomboid, deviator 60 comprising a body 62 provided with entrance and exit windows 64 and 64A respectively and parallel flat reflectors 66 and 66A. The light path is delineated at 68.
FIG. 8 shows, diagrammatically, a 180 degree deviator 70 comprising body 72, entrance and exit windows 74 and 74A respectively, a plane reflector 76 and a roof prism 78. The light path is shown at 80.
A relatively simple boresighting arrangement using one zero degree deviator 60 and one 180 degree deviator 70 is shown in FIG. 9. Here, collimated light from projector 10 passes through window 64 of deviator 60, is reflected by mirrors 66 and 66A and exits through window 64A into window 74 of the 180 degree deviator 70, is reflected by mirror 76 and prism 78 and passes out of window 74A to a receiver 30. In the example shown here deviators 60 and 70 are joined at a hinge 82. If the image received at the position sensitive detector is not imaged at the latter's center, an electrical signal results indicating the direction and degree of departure from that center.
FIG. 10 is a schematic showing of a pair of deviators similar to those of FIG. 7 in which the two deviators are swiveled at hinge joint 82 to have an angular relationship other than a straight line and to thereby allow flexibility in the extension distance. The deviators are provided with counterweights 84 to aid in holding their positions. Because of the high accuracy in mirror and prism position as well as that of the hinge, the integrity of a beam of collimated light from a projector entering window 64 is not lost or altered when it exits window 64A.
A somewhat more detailed showing of the zero degree deviator is shown in FIG. 11. Here, reflectors 66 and 66A are mounted at the ends of a rigid tube 86. Tube 86 is mounted at one end by means of a diaphragm 88 to outer body 62. At the other end it is supported by body 62 through a bearing 90. Diaphragm 88 and bearing 90 isolate the mirrors and their interrelationship from the effects of flexing of body 52, thereby insuring that the deviated beam is parallel to the incident beam. Suitable means such as feet 92 may be provided for supporting the deviator body on a convenient structure on the aircraft. When used to perform the full boresighting task on an aircraft, the system of the present invention uses a pair of the projectors of FIGS. 1 to 4 attached to adjacent faces of a primary reference cube. The latter is itself previously accurately positioned with respect to the aircraft's boresight reference line and there held on an appropriate fixture. One projector can be arranged to measure pitch and yaw while the second can measure roll and yaw. If the optical path to the receivers is of moderate length, a pair of deviators are sufficient to bring the collimated light beam to the receivers. If the path length is so long as to require excessively long deviators whose integrity may be threatened because of uncompensatable bending, a transfer cube, described below, is used. The final receivers are attached to adjacent faces of a cube positioned at the boresight by means of a suitable fixture.
FIG. 12 shows such an arrangement. A cube 14A, designated the primary reference cube, is locked in place at the boresight reference line. A pitch/yaw projector and a roll/yaw shown at 10 and 10A respectively are attached to cube 14 in the manner of FIGS. 1 to 6 or equivalent. Assuming that the path length is too great for a pair of deviators to span with convenience, an intermediate, or transfer cube 14B is held on pads fastened to any a convenient point on the aircraft structure or independently. Fixed on adjacent faces of cube 14B are a receiver 40A for pitch/yaw and a receiver 40B for roll/yaw. At the opposite faces on this cube are the corresponding pitch/yaw and roll/yaw projectors 10B and 10C respectively, which continue the collimated lines of sight.
At the boresighting station which may be a weapon, sight, forward looking infrared device or other apparatus, a third optical cube 14C is attached, carrying a pitch/yaw receiver 40C and a roll/yaw receiver 40. Pitch/yaw projector 10 is optically coupled to pitch/yaw receiver 40A through deviators 70 and 60. Secondary pitch/yaw projector 10B picks up the line of sight and through deviators 60A and 70A brings the collimated beam to pitch/yaw sensor 40C. Similarly, roll/yaw projector 10A sends its collimated beam via deviators 70B and 60B to receiver 40B. Secondary roll/yaw projector sends its collimated beam via deviators 60C and 70C to roll/yaw receiver 40D at the boresighting location. The signals from receivers 40C and 40D are processed to yield pitch, yaw and roll data.
It is also possible to obtain roll data by reference to gravity. In this modification, not shown, the transmitter and receiver each use a pendulum mirror in place of mirrored face 12. A transmitter-receiver pair is attached at the reference cube on the roll/yaw surface. A similar pair is attached at the station being boresighted. The difference is a measure of roll.
Obviously, if the line of sight between a projector at the primary reference cube is direct and relatively short, a transfer cube becomes unnecessary. Such a situation is illustrated in connection with pitch/yaw projector 10 where an alternate arrangement of deviators 70D and 70E can provide a direct path 94 to pitch/yaw detector 40C.
FIG. 13 shows the block diagram for the pitch and yaw read-out unit. Here the output of the position sensor in receiver 40C is processed in turn by transimpedance amplifiers 100, differential amplifiers 102, summing amplifier 104, dividers 106, rectifier 108, squarer 110 and inphase rectifiers 112 to yield separate pitch and yaw data at displays 114 and 116 respectively.
Transimpedance amplifiers 100 convert the photocurrents from the position sensor into voltages which the differential amplifiers show as differences in the outputs of the position-sensitive sensor. The summing amplifier sums this output which is fed to the dividers which divide the resulting AC difference signal by the rectified sum signal to normalize the output. The AC sum signal is then squared by the squarer for a proper phase rectification of the displacement signal and the rectifiers develop a DC voltage which is proportional to the peak displacement signal amplitude.
FIG. 14 is a block diagram of the complete electronic system for the boresighting system comprising transmitter 118 and receiver 120. The former includes the laser driver and modulator for the lasers in projectors 10 and 10A of FIG. 12. The light beams from projectors 10 and 10A are received by the position sensitive sensors in receivers 40C and 40D for pitch/yaw and yaw/roll respectively. The top half of receiver 120 shows in simplified block form the block diagram of FIG. 13. The bottom half of receiver 118 is identical to FIG. 13, processing out the roll data to display 122 and discarding the already available yaw data. | In a weapon boresighting system for aircraft and vehicles, an optical square is oriented to a fixed reference line on the vehicle and provides the directionality of a pair of orthogonally positioned of laser illuminated retroreflective catadioptric collimators attached to said optical square whose outputs are directed via one or more deviators or periscopes to a pair of retroreflective catadioptric receivers orthogonally attached to a second optical square positioned at the weapon to be boresighted, each said receiver imaging the laser on a position sensitive sensor, the outputs of the latter indicating the pitch roll and yaw condition at the weapon. | 5 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to cooling of a mold used in a blow-molding process, and more particularly to cooling a mold or sections of a mold by recovering energy from the compressed air or gas used to operate a molding machine and to shape the containers in the mold.
[0002] In a typical blow-molding process employed in the manufacture of plastic containers, such as PET (polyethylene terephthalate) bottles, the plastic starting material is heated to about 95° C., which is 20° C. above its glass transition temperature. The supplied heat softens the plastic starting material so it can be stretched to and shaped to fill the mold. Compressed air at a pressure of about 30 bar and a temperature between about 20° C. and 30° C. is blown in the interior of a preform of the container, urging the container against the walls of the mold. The container hereby takes on the shape of the mold cavity.
[0003] Before the blow-molded container is removed from the mold, the mold is cooled to below the glass transition temperature of the plastic material, i.e., below about 70° C. for PET. In current molding machines, the mold is cooled by flowing chilled water at about 12° C. through cooling channels arranged in or on the mold. The water is chilled in a closed-loop refrigeration system and pumped through insulated pipes systems to the blow mold, where it flows through the cooling channels. During the molding process, the water temperature rises by about 2° C. The water is then returned from the mold to the refrigeration system to remove heat.
[0004] Water-cooled systems are subject to scale buildup and corrosion, are expensive to maintain and require a supply of external energy to chill the water, while the energy contained in the compressed gas used in the blow-molding process is wasted, as the compressed gas is simply vented to the ambient environment.
[0005] It would therefore be desirable to provide a system and method for cooling a blow-molding machine using less energy.
SUMMARY OF THE INVENTION
[0006] The present invention provides a system and method for cooling a blow-molding machine using less energy. The invention also achieves the result of recovering otherwise-wasted energy from the compressed gas used for blowing the mold and operating the machine. The recovered energy is used for cooling the mold.
[0007] According to one aspect of the invention, a cooling arrangement for a mold of a blow molding machine includes an expansion cooler having a high pressure side and a low pressure side, wherein the high pressure side receives pressurized gas at a first temperature used for molding an article in the blow molding machine, and a cooling channel disposed in the mold and receiving gas from the low pressure side of the expansion cooler at a second temperature lower than the first temperature. The gas at the second temperature flows through the cooling channel and cooling the mold.
[0008] According to another aspect of the invention, a method for cooling a mold of a blow-molding apparatus includes the steps of exhausting gas at a first temperature from a pressurized compartment of the blow-molding apparatus through an expansion cooler to provide a flow of gas at a second temperature lower than the first temperature, and directing the gas flow at the second temperature through a cooling channel in a mold to cool the mold.
[0009] Advantageous embodiments may include one or more of the following features. The cooling arrangement may include a manifold configured to supply the pressurized gas to an interior volume of the article to be molded and to exhaust the pressurized gas from the molded article to the high pressure side of the expansion cooler. The expansion cooler may have a Venturi constriction.
[0010] In one embodiment, at least one vortex tube may be placed between the low pressure side of the expansion cooler and the cooling channel. The vortex tube has an inlet port configured to receive the gas from the low pressure side of the expansion cooler and a cold outlet port in fluid communication with the cooling channel. Cold gas from the cold outlet port passes through a cooling channel in the mold and cools the mold. More than one vortex tube may be employed, as the mold may include several mold sections with separate cooling channels. The different vortex tubes can be connected to different cooling channels in the various mold sections.
[0011] In one embodiment, a reservoir may be disposed upstream of the at least one first vortex tube, with the reservoir having a pressure intermediate between the pressure of the pressurized gas and the pressure at the outlet port of the vortex tube or tubes. The intermediate pressure is preferably constant, independent of a mold cycle of the blow molding machine.
[0012] The blow-molding apparatus may include one or more actuators, which may be pneumatically operated, for connecting a blow nozzle to the mold neck and operating a stretching rod for stretching a preform of the article. Gas exhausted for the actuator(s) and/or from any other pressurized section of the molding apparatus may be routed through another vortex tube, which may then also supply cold gas to the cooling channels. Preferably, the pressurized gas exhausted from at least the actuator and the pressurized gas exhausted from the pressurized molded article are the only sources of energy cooling the mold.
[0013] Cyclic operation of the blow-molding apparatus can be timed by a timing circuit configured to operate the various valves, manifolds, actuators, etc. Additional energy can be recovered from the hot outlet ports of the various vortex tubes, with the hot gas to be used, for example, for raising or maintaining a temperature of the preform or heating the mold body to control container shrinkage.
[0014] The article to be molded can be made of a plastic material, and the gas temperature at the cold gas outlet port of the vortex tubes may advantageously be adjusted to be below the glass transition temperature of the plastic material.
[0015] Further features and advantages of the present invention will be apparent from the following description of exemplary embodiments and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The above and other objects and advantages of the invention will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:
[0017] FIG. 1 shows a conventional system for cooling a blow mold; and
[0018] FIG. 2 shows a system according to the invention for cooling a blow mold.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The invention is directed to systems and methods that efficiently cool a mold at the conclusion of the molding process to facilitate removal of a dimensionally stable container from the mold. In particular, the systems and methods described herein can recover energy from the compressed gas employed in the blow-molding process. The recovered energy is used for cooling the mold, thereby saving energy compared to conventional cooling methods that employ recirculating chilled water cooling.
[0020] FIG. 1 shows schematically a conventional blow molding system 10 , which includes a mold 12 with a mold bottom 12 a , side sections 12 b , 12 c , and a mold neck 12 d . The mold bottom 12 a , side sections 12 b , 12 c , and mold neck 12 d may be separable to facilitate un-molding a finished container 11 . Although the mold 12 is shown as having two side sections 12 a , 12 b , it will be understood that the mold 12 may have only one side section or more than two side sections. Cooling channels 13 a , 13 b , 13 c for cooling the mold 12 pass through the mold sections 12 a , 12 b , 12 c and 12 d.
[0021] In a blow-molding process, a container is formed by heating a preform (a small tube of plastic with the cap threads pre-molded into the plastic) made, for example, of PET to about 95° C., for example, in an infrared oven. At this temperature the plastic becomes soft. The heated preform (not shown) is then placed inside the mold 12 , and a blow nozzle 15 is lowered by an actuator, such as the illustrated exemplary pneumatically operated linear actuator 28 , or by a cam (not shown), sealing against the preform in the mold. The actuator 28 or cam in the illustrated embodiment is operated by compressed gas having a pressure of between about 3 bar and about 7 bar. The gas is supplied to a respective chamber of actuator 28 via a 4-port valve 29 to move a piston 28 a . Air from the other unpressurized chamber is exhausted to atmosphere 49 through a check valve 48 .
[0022] Once the preform is sealed inside the mold, a stretch rod 27 is lowered at a specific mechanical rate, for example, with the same actuator 28 or with a different actuator (not shown), thereby stretching the preform to at least partially fill the mold cavity.
[0023] Compressed air from exemplary air supply 17 is introduced through line 14 c , a three-way valve 16 , line 14 a and blow nozzle 15 into the interior of the preform, first at a relatively low pressure (between about 6 and about 15 bar), to evenly distribute the plastic inside the mold. The three-way valve may be cam or solenoid operated, or energized by any suitable actuator known in the art. Once the preform is fully stretched, the gas pressure is increased to between about 30 bar and about 40 bar to urge the preform against the interior surface(s) of the mold and achieve definition. Compression of the gas causes the gas inside the preform to heat up. As the expanded preform touches the mold cavity, thermal energy from the hot gas inside the preheated preform is transferred to the mold 12 .
[0024] After the container is formed, the actuator 28 raises the connected stretch rod 27 out of the newly formed container, the cam operated three-way valve or solenoid valve 16 opens and the container is exhausted to atmosphere 49 . The blow nozzle 15 is raised by either a cam or a pneumatic actuator and the newly formed container is removed from the mold. The energy stored in the pressurized gas is essentially wasted in a conventional blow-molding machine.
[0025] Before the finished container 11 can be removed from the mold 12 , the mold 12 needs to be cooled below the glass transition temperature of the plastic container material. This is achieved by continuously flowing a coolant through the cooling channels 13 a , 13 b , 13 c , possibly during the entire molding cycle, and not only when the container is removed from the mold. The coolant also needs to be chilled which requires additional energy.
[0026] A typical blow-molding machine can manufacture containers at a rate of 18 to 30 containers per minute per mold, depending on the machine capacity. In the following example, a container size of 1 liter is assumed, although the system can operate with other containers sizes. The heat transferred to the mold is proportional to the gas volume and hence to the internal volume of the produced container, i.e., smaller containers transfer less heat to the mold which then requires less cooling.
[0027] The compressed air used to form a 1 liter container is at a pressure of 30 to 40 bar (435-580 psi). Assuming that between about 18 and about 30 containers are manufactured per minute and per mold, this represents between about 18 and about 30 liters of compressed air per minute per mold cavity at between about 30 bar and about 40 bar of pressure, or between about 0.6 m 3 /min and about 1.0 m 3 /min for a 34-cavity machine at that pressure. Additional compressed air at an operating pressure of about 7 bar is used by the actuator that operates the stretching cylinders 27 and the blow nozzle 15 and from other pressurized sections of the machine. This additional volume is between about 1.5 m 3 and about 2 m 3 for the 34-cavity machine at that operating pressure. The entire air volume contained in the actuator(s) or cam(s) that move the blow nozzle and stretch rod, as well as the valve actuators, can be used for cooling the mold in accordance with the method of the invention.
[0028] FIG. 2 shows schematically an exemplary blow-molding system 20 according to the invention which, unlike the conventional system of FIG. 1 , recovers the energy from the compressed gas to cool the mold 12 or at least parts of the mold 12 , such as the mold neck 12 d . The mold 12 of system 20 is substantially identical to mold 12 of system 10 depicted in FIG. 1 and includes mold bottom 12 a , mold sections 12 b , 12 c , and mold neck 12 d . Cooling channels 13 a , 13 b , 13 c for cooling the mold extend inside the various mold sections 12 a , 12 , 12 c , 12 d.
[0029] As before, actuator 28 , which may be implemented as a cam, may, for example, be pneumatically driven from compressed gas source 39 having a pressure of between about 3 bar and about 7 bar. Stretch rod 27 preferably is lowered by actuator 28 to stretch the preform inside mold 12 , whereafter the container preform may be pressurized to between about 30 bar and about 40 bar from compressed gas source 17 via 3-way valve 16 and gas line 14 a connected to blow nozzle 15 , to urge the preform against the interior surface(s) of the mold and achieve definition. However, instead of being vented to atmosphere at the conclusion of each molding cycle, as in the conventional system 10 , the pressurized gas remaining inside the finished container flows through gas line 14 a and 3-way valve 16 and line 24 b and further through a check valve 32 and a direct expansion diffuser (e.g., a Venturi jet) 18 to a gas reservoir 26 . Alternatively, it may be possible to use a vortex tube, as described below, instead of the expansion diffuser 18 to cool the pressurized gas. The gas reservoir 26 may be maintained at a pressure of, for example, between about 3 bar and about 7 bar. The temperature of the gas in reservoir 26 after expansion can be below ambient temperature, for example, at a temperature between about 10° C. and about 20° C., depending on the operating conditions, such as flow rate and pressure.
[0030] While the gas flow through lines 14 a , 24 b before expansion diffuser 28 is typically intermittent—for example, between about 18 times and about 30 times per minute for synchronously operating mold cavities—reservoir 26 may “buffer” those pressure fluctuations so that the pressure in reservoir 26 remains substantially constant. Any excess pressure is preferably vented via a safety relief valve 42 which may be located on the reservoir 26 .
[0031] Reservoir 26 is connected via a manifold 22 to the high-pressure side of one or more vortex tubes 23 a , 23 b , 23 c . A vortex tube, such as exemplary vortex tube 23 a , has an inlet port 231 (typically a side port) for the compressed gas, an outlet port 232 located at one end of the vortex tube and delivering an adjustable volume fraction of cooled gas (also referred to as cold end), and another outlet port 233 located at the opposite end of the vortex tube for delivering a complementary volume fraction of the hot gas heated in the vortex tube (also referred to as hot end). The volume fraction and the temperature of gas released from the cold end 232 of a vortex tube can be adjusted by adjusting the percentage of input compressed gas released through the cold end of the tube, which percentage may be referred to as the “cold fraction.” The cold fraction is also a function of the type of vortex tube in the vortex tube—i.e., the vortex tube can be designed as a “high cold fraction” generator or as a “low cold fraction” generator. A vortex tube with a low cold fraction, i.e. with a smaller volume percentage of the total gas input exiting at the cold end of the vortex tube, will typically result in a lower temperature of the gas at the cold end.
[0032] The vortex tubes 23 a , 23 b , 23 c reduce the temperature of a portion of the gas supplied from the reservoir 26 to the respective inlet ports of the vortex tubes 23 a , 23 b , 23 c and exiting at the cold ends. The vortex tubes 23 a , 23 b , 23 c preferably are sized to accommodate the total flow of between about 0.6 m 3 /min and 1.0 m 3 /min of the compressed gas exhausted from the finished molded containers.
[0033] The gas exiting the cold end of vortex tubes 23 a , 23 b , 23 c preferably flows through the connected cooling channels 13 a , 13 b , 13 c disposed in mold sections 12 a , 12 b , 12 c , 12 d . In the vortex tubes 23 a , 23 b , 23 c , the gas pressure drops from between about 3 bar and about 7 bar in reservoir 26 to about 1 bar at the respective cold-fraction ports. Valves 33 a , 33 b , 33 c may be connected between the vortex tubes 23 a , 23 b , 23 c and the respective flow channels 13 a , 13 b , 13 c , or at any other suitable location in the gas flow passageways for connecting and/or adjusting the flow of the cold gas. The vortex tubes 23 a , 23 b , 23 c preferably are sized to match the total flow rate through cooling channels in the individual mold cavities.
[0034] If the mold is cast (e.g., in the case of an aluminum mold), the cooling channels in the mold may be formed as small passageways during casting. Alternatively, or in addition, the cooling channels can be drilled into the mold sections in, for example, a simple cross drill pattern. After flowing through the passageways 13 a , 13 b , 13 c and absorbing heat from the mold (sections), the gas used to cool the mold is preferably exhausted through baffles 25 a , 25 b , 25 c to reduce noise. It has been demonstrated that the temperature of air entering a vortex tube at a pressure of about 1.5 bar and with a flow rate of about 0.3 m 3 /min can be lowered by about 28° K. This chilled air may pass through the mold cooling channels and remove the heat generated by the blow-molding process, preferably without requiring additional cooling power.
[0035] Additional energy can be recovered from the compressed gas operating the actuator 28 , the stretching cylinder 27 and the blow nozzle 15 , which has about the same pressure as the gas in reservoir 39 . This gas can also be directed through an additional vortex tube 23 d to provide an additional flow of cold gas at the cold end of additional vortex tube 23 d . The outlet of vortex tube 23 d can be connected to any one of cooling channels 13 a , 13 b , 13 c or to a combination of these cooling channels. It will be understood that throughput of vortex tubes 23 a , 23 b , 23 c , 23 d should be appropriately matched to the capacity of cooling channels 13 a , 13 b , 13 c.
[0036] A timing circuit 40 , which may already be part of a conventional molding system, may be connected to the various valves 16 , 33 a , 33 b , 33 c , and the actuator 28 to properly time insertion of the preform into the mold, pressurization of the preform and depressurization of the molded article, and removal of the molded article from the mold.
[0037] The hot gas exiting the vortex tube 23 a at the hot end 233 can be directed through a heat exchanger (not shown) to preheat the preforms before these enter a preheat oven or while the preheated preforms are transported from the preheat oven to the blow wheel, thereby recovering additional energy.
[0038] Excess recovered cold air (not shown) can be used to cool the neck barrier of the container in the oven to prevent distortion of the threaded neck finish, again using the cold end of a vortex tube for supplying the cooled air.
[0039] In summary, methods and systems have been described that use the thermal energy of compressed gas from pressurized sections of a blow-mold to cool the mold when removing the molded articles. The process saves energy which would otherwise have to be expended for chilling a coolant, for example, cooling water or a gas.
[0040] While the invention has been disclosed in connection with the preferred embodiments shown and described in detail, various modifications and improvements thereon will become readily apparent to those skilled in the art. For example, the vortex tubes and direct expansion diffusers may be used in combination or their role may be interchanged. One skilled in the art will appreciate that the present invention can be practiced by other than the described embodiments, which are presented for purposes of illustration and not of limitation, and the present invention is limited only by the claims which follow. | Heat is extracted from compressed gas used in a blow-molding process by expansion cooling the exhausted gas and/or passing the exhausted gas through a vortex tube, which supplies cold gas at an exit thereof. The cold gas is then routed through cooling channels in the mold. This obviates the need for recirculating or externally chilling a coolant and saves energy. | 8 |
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BACKGROUND OF THE INVENTION
This invention relates to sensor arrays, and especially to passive optical sensor arrays that are located in environments in which the sensor array is difficult to access. The invention is particularly suitable for undersea seismic sensor arrays, although it will be appreciated that the invention may be employed with sensors of other types. For example, the array may be employed with electric field sensors for determining the presence of oil by changes in the electric field as the conductivity of the rock that contains the oil changes. In other systems, the array could be part of a security warning system that contains a number of hydrophones for detecting unauthorised vessels.
Undersea seismic sensor arrays are widely used in the exploration of and monitoring of oil and gas reservoirs beneath the seabed. In these seismic monitoring techniques, an array of accelerometers and/or hydrophones are deployed as sensor packages on the seabed and are used to detect reflected seismic waves, and the results are analysed to provide information relating to the nature and state of geological structures beneath the seabed.
Typically a large number of sensors, for example 16,000 or more, are arranged along a number of optical cables that are spaced apart from one another to form a two-dimensional array that extends over a large area for example an area of 100 square kilometers or more. In one form of arrangement which may be referred to as a “4C” sensor unit, three seismic vibration sensors are arranged in orthogonal directions together with one hydrophone to form an optical sensing unit (OSU), and a number of optical sensing units are located along an optical line at spaced apart intervals, for example in the range of from 20 to 100 meters. A number of lines, for example 30 although more or fewer may be employed, may extend from a hub located on the seabed in a direction generally parallel to one another and spaced apart from one another, for example by from 100 to 500 meters, to form the array. The hub may be connected by an optical cable to an interrogator located on an exploration or production platform or on a floating production and storage offloading vessel (FPSO) that monitors the sensors by reflectometry or other interferometric means. The optical cable will contain at least one optical fibre for each of the lines that extend from the hub (typically one fibre pair). In operation, the interrogator sends an optical pulse along the cable where it is split at the hub before being sent along the individual lines to the optical sensor units. The vibration sensors may comprise a length of optical fibre that is wound around a flexible former to form a coil, and the optical lines may contain reflectors, for example formed by a mirror that terminates a fibre spliced with the line, preferably upstream and downstream of the sensors. As the external pressure varies, the coil of fibre is compressed or released, thereby changing the length of fibre in the coil. If a signal is sent along the optical fibre, it is partially reflected back along the line at each of the mirrors so that the signal, for example a phase shift in the signal that is dependent on the distance between the reflectors, is affected by any seismic activity. In this way, any mechanical impulse caused by an air gun or other explosion in the vicinity of the array will cause a phase change in signals reflected by the sensors in the array which may be observed by the interrogator.
The signals that are sent along the optical lines will normally be multiplexed in view of the large number of sensor units, usually both time division multiplexed and wavelength division multiplexed.
The interrogator of the system thus typically comprises a transmitter having a number of light sources such as lasers, e.g. 16 , for forming the optical signals, and optical switches, and a receiver for receiving and processing the reflected optical signals. The receiver will need to demultiplex a number of wavelength and time division multiplexed streams arriving from the various optical lines of the sensor array, convert the optical signals to electrical signals, digitise them and transmit them onwards or store them. The interrogator is normally the only part of the system which contains electronics or requires electrical power.
Such sensor arrays may include a large number of optical fibre pairs, for example 100 to 200 pairs or more depending on the size of the array, and even up to 700 fibres in some cases, and these will extend from the hub to the platform or FPSO in the form of a riser cable which extends generally vertically from the seabed, although there may be a significant horizontal component, whereupon the cable will extend to a receiver unit of the interrogator located on the platform or FPSO.
While such systems generally work well in practice, they can have a number of problems. For example, in some forms of design where the sensor array is a long distance from the interrogator this would require a riser cable with 100 to 200 fibre pairs extending in the region of 100 km or more between the interrogator and the array, which can be impractical and extremely costly. In other circumstances the platform or FPSO may employ existing optical cables for receiving data from the array, in which case it may not have sufficient optical fibres in the riser. For example many installations may employ existing optical cables having only six fibres or so. In yet other instances, it can be difficult to direct the fibres in the cable from the riser to the interrogator and, in many circumstances, such a riser cable termination is not possible. For example, in the case of an FPSO, the riser cable may emerge onto a stationary turntable whereas the rest of the interrogator will be located on the vessel which may rotate about the turntable at least to a limited extent due to tides and currents etc. This will often require some means of allowing the optical fibres to rotate about the axis of the riser cable at least to a limited extent, for example a slip ring otherwise called a fibre optic rotary joint, to allow the optical fibres to extend between the riser cable and the interrogator on the FPSO. However, such slip rings typically only accept a few optical fibres and even the largest number of optical fibres that can be accepted by a slip ring ( 31 at this time) is only a fraction of the number of optical fibres in a typical riser cable, so that seven slip rings would be required. Furthermore, the specification of such a slip ring is insufficient for the purpose of a seismic optical fibre array in many cases since the two-way insertion loss may be 9 dB bringing the insertion loss of the array above 60 dB in some cases. In addition, the minimum return loss of the slip ring may be 18 dB, which means that back reflections my be sent to the array degrading its performance, or alternatively isolators would be required in order to prevent such back reflections. Finally, the physical size of the interrogator may be quite large, in the order of two or three cubic meters, and there may not be enough space on the platform or FPSO for the interrogator.
BRIEF SUMMARY OF THE INVENTION
According to one aspect, the present invention provides a sensor arrangement for monitoring a submarine reservoir, which comprises:
a sensor array comprising a plurality of sensor units located or to be located over an area of the seabed in the region of the reservoir to be monitored; and
an interrogator unit for obtaining data on the reservoir from the sensor units, which comprises a transmitter unit for sending optical signals to the sensor array, and a receiver unit for receiving modulated optical signals from the array in response to the transmitted optical signals;
the transmitter unit comprising an optical switch, for example an acousto-optical modulator (AOM) for receiving optical radiation from an optical source and transmitting optical signals generated thereby along an uplink optical fibre, and at least one splitter for splitting the uplink optical fibre into a plurality of optical fibres that extend to the sensors over the area to be monitored; and
the receiver unit comprising an optical-to-electrical converter for converting optical signals from each fibre of the array to electrical signals, a phase demodulator, a multiplexer for multiplexing the electrical signals from the phase demodulator, and a signal processing and recording unit for recording the multiplexed signals.
The interrogator unit may be divided into a concentrator and an interrogator hub, the concentrator including the splitter and the optical-to-electrical converter, phase demodulator and multiplexer of the receiver unit and the interrogator hub including the optical source and optical switch of the transmitter unit, the signal processing and recording unit, such that the optical source, optical switch, signal processing and recording unit can be located on a platform or on shore, and the electrical-to-optical converter, phase demodulator and multiplexer can be located on the seabed.
The interrogator unit may include means for transmitting signals from the or each concentrator to the interrogator hub along a single line or wirelessly.
The sensor arrangement according to the invention has the advantage that, by dividing the receiver, and preferably the transmitter and receiver, into two parts, one underwater (the concentrator) and the other above water (the interrogator hub), and by multiplexing the signals from the sensor array in the underwater part of the receiver, only a small number of optical fibres are needed in the riser extending between the submerged part of the interrogator and the surface part. The particular number of optical fibres in the riser between the submerged and surface part of the interrogator will depend on the particular design of arrangement, but it is possible to employ only a single optical fibre for the uplink (i.e. from the transmitter to the array) and a single further optical fibre in the downlink (unless the signals are transmitted from the concentrator to the interrogator hub wirelessly) so that the riser contains only a single pair of fibres. Other optical fibres may be necessary or desirable depending on the circumstances as explained below.
The optical fibres extending from the interrogator hub to the array are preferably arranged spatially in proximity to the return fibres extending from the array to the interrogator hub, and especially together so that the sensors are connected to the hub by means of optical cables formed from a pair of fibres. In addition, the interrogator unit may have a number of configurations. For example in one design it may have only a single concentrator from which a number of fibres extend to the sensor array, each line of the array being formed from a pair of fibres. In another design, an optical cable formed from a relatively small number of optical fibres may extend from the interrogator hub to a passive hub where it branches into a number of further optical cables, each extending from the passive hub to a concentrator and typically having two fibres (one uplink carrying transmit pulses and one downlink containing digitised sensor data). From each concentrator the fibres extend to the array as described above. Such a design of array will contain more than two optical fibres in the riser cable, for example up to six or eight fibres or even more, but nothing like the number of fibres employed in prior art systems. Other configurations of array are also possible.
In some circumstances other fibres may be present, for example for sending timing signals to synchronise the transmitter and receiver. For example a further optical fibre for synchronisation may be present extending directly from the transmitter in the interrogator hub to the submerged part of the receiver, that is to say, bypassing the sensor array, although such an arrangement is not preferred since it will increase the number of fibres in the riser. Alternatively, timing signals may be sent from a synchronisation unit in the interrogator hub both to the acousto-optical modulator in the transmitter and to the phase demodulator and/or multiplexer of the receiver unit along the uplink or downlink optical fibre extending along the riser cable. In yet another arrangement, timing signals may be sent along an optical fibre extending on the transmitter side of one or more of the sensors in the array to the phase demodulator, for example in proximity to the downlink optical fibres extending from the array. Only a single such optical fibre is required for a complete array. In addition, it is possible for different fibres in the riser to send signals to and from different parts of the array of sensors depending on the layout of the array, but in such cases it is unlikely for more than six to eight optical fibres to be present in the riser.
It is possible for the concentrator(s) of the interrogator to be permanently secured to the seabed, especially if the electronic parts thereof are relatively simple, but the concentrator could be provided in a watertight module that is submersible and which can be raised up to the platform or FPSO for maintenance or repair but which otherwise remains on the seabed. Such a module may be provided with a stowage/deployment arrangement for stowing the riser cable when the module is raised and for deploying the cable when the module is lowered to the seabed.
Where the concentrator requires electrical power to be supplied, this may be supplied via the link to the interrogator hub, through a separate electrical cable from the platform shore or other seabed location, or via a local battery.
Although the interrogator hub and concentrator will often be located close to each (with one on the surface and one underwater) it is possible for the concentrator and the interrogator hub to be separated from one another, even by a large distance for example by up to 100 km or so.
Although the concentrator is normally located underwater, and the interrogator hub on the surface, in certain circumstances both may be located on the surface, for instance when the concentrator is located on a fixed turret and the interrogator hub on the rotating portion of a floating production platform (FPSO). In these cases, the concentrator is usually located at a location where space and power requirements may be limited, and it is desirable to minimise the number of optical fibres in the connection between the concentrator and the interrogator hub.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
One form of arrangement in accordance with the present invention will now be described by way of example with reference to the accompanying drawings in which:
FIG. 1 is a schematic view of a conventional seismic sensor arrangement;
FIG. 2 is a schematic view of one form of sensor array topography according to the invention;
FIG. 3 is a schematic view of another form of sensor array topography according to the invention;
FIG. 4 is a schematic view of an FPSO in which an arrangement according to the invention may be used;
FIG. 5 is a schematic diagram showing the principal parts of the arrangement according to the invention;
FIG. 6 is a schematic view showing part of the arrangement of FIG. 5 which uses a derivative sensor technique (DST); and
FIG. 7 is a schematic view of an arrangement that employs a submersible module.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , there is seen a marine oil platform 7 , supported on legs from the seabed. A seismic sensor array 1 as described in GB 2 449 941 is deployed on the seabed in order to detect changes in the underlying reservoir. The seismic sensor array comprises a plurality of seismic cables 2 each of which may be formed from a number of modules 3 that are joined by joint elements 4 and contain a number of sensor units 5 that are spaced apart along the cables. The connecting seismic cables 2 lead to a passive hub 8 , where all of the seismic cables 2 are joined to form a riser cable that extends from the hub 8 to an operating system 6 on the platform 7 . Signals are generated by a transmitter in the operating system or interrogator 6 and sent to the sensor units 5 , and returns are received from the sensor units 5 at the operating system 6 , where the signal returns are analysed in order to determine the nature of the structures beneath the seabed. As indicated above, this form of array has the disadvantage that the riser cable will need to employ a large number of optical fibres, for example from 50 to 200 fibres or more.
As shown in FIG. 2 , one form of sensor array similar to that shown in FIG. 1 is shown in which a riser cable 10 comprising just a pair of optical fibres extends from an interrogator hub 11 that is located on the platform and includes a transmitter unit and receiver unit. The cable extends to a concentrator 12 located on the seabed in the region of the platform where the optical fibres in the cable are split to form a number of separate seismic cables 14 corresponding to the cables 2 of FIG. 1 which extend from the concentrator over the region of interest. In addition, a slip ring 15 may be located at the interrogator hub in order to accommodate relative rotational movement between the riser cable and the interrogator hub.
An alternative topography for the sensor is shown in FIG. 3 in which a riser cable 10 comprising in this case six optical fibres extends from the interrogator hub 11 to a passive hub 16 where the optical fibres are divided into three separate optical cables 17 , each having a pair of fibres. Each of the optical cables 17 extends to a concentrator 12 where the fibres in the cable are split as before to form a number of seismic cables 14 .
A sensor unit 5 that may be employed in the sensor typically comprises three seismic sensors arranged in orthogonal directions and a hydrophone. Each seismic sensor is in the form of a coil of optical fibre wound around a former whose diameter will vary slightly when subjected to seismic vibrations so that the length of the optical fibre coil will also vary. Between the coils of optical fibre are arranged mirrors or other reflection devices such as Bragg gratings, so that a signal sent along the optical fibre will be reflected by each mirror to form a pair of pulses whose separation will depend on the length of the optical fibre winding. Such sensor units comprising three orthogonal seismic sensors and a hydrophone may be referred to as an optical sensing unit (OSU). The sensors may also be connected in other ways well known in the field, for instance in a transmissive coupler configuration
The seismic sensors and hydrophone are fibre optic devices, and the connection cable will comprise a number of optical fibres for connecting the sensors of each sensor unit to its neighbours in the chain. In one embodiment, a continuous length of cable 2 may connect all of the sensor units in a deployment device. The cable may have a number of optical fibre pairs running along its length, and at each sensor unit a single fibre may be drawn out of the cable and connected to the sensors of that sensor unit.
Each optical sensing unit (OSU) will require four channels (one for each seismic sensor and one for the hydrophone) and may be deployed in groups of four, which require 16 optical channels per group. This may conveniently be achieved by time division multiplexing, in which the input optical signal is pulsed and returning optical pulses from different sensors are distinguished by time of flight. Additional multiplexing that is required in order to interrogate all the optical sensing units is achieved by means of wavelength division multiplexing, in which pulses of a number of different wavelengths, typically 16, are sent into the system and each wavelength is routed to a separate set of time multiplexed sensors using commonly known wavelength selective components. The received signals are therefore sent from the optical sensing units to the receiver as a number of time division multiplexed and wavelength division multiplexed streams. The optical signal from each sensor contains the data from that sensor encoded as a phase modulation. Typically, the receiver may receive in the order of 30 different TDM/WDM streams corresponding to 480 channels. An implementation of this architecture is described in European Patent No. EP 1 169 619 B1.
In addition to being deployed on a fixed oil production platform as shown in FIG. 1 , the arrangement may be terminated on a floating production and storage offloading vessel (FPSO) shown schematically in FIG. 4 . This is essentially a vessel 10 having a fixed turret 11 through which the riser cable extends. The vessel is tethered by means of cables 14 , but the vessel may yaw to some extent by virtue of waves, currents and tides, so that the vessel 10 may rotate around the fixed turret 11 . The interrogator 16 is located on the vessel.
FIG. 5 is a schematic diagram showing the principal layout of the arrangement according to the invention. The arrangement comprises an interrogator forming the main part of the diagram which comprises an interrogator hub 20 and a concentrator connected to each other by a riser cable. The interrogator sends signals to a sensor array as shown in FIGS. 2 and 3 , one line 1 of which is shown, and receives, processes and stores return signals from the array. The interrogator comprises a transmitter for sending an optical drive signal to the array comprising a high specification laser source 22 for generating a constant optical signal and an acoustic optical modulator (AOM) 24 (or other suitable optical switch as such an electro-optic switch) for pulsing and frequency shifting the optical signal. Typically the AOM will produce a pair of pulses, one of which is time delayed and frequency shifted by typically 50 KHz with respect to the first pulse, from the transmitter to the array so that a train of pulses is reflected by the mirrors located between the sensor coils of the OSUs within the array. If the time delay of the second pulse corresponds to the time taken for a pulse to travel through one coil between the two mirrors and its return following reflection by the mirror on the far side of the coil, pulses will be generated which are a superposition of initial and time delayed pulses 26 reflected by different mirrors in the array, and this superposed pulse, which is at a difference frequency of typically 50 kHz, carries the phase information from the sensor between those mirrors as a phase modulation of the carrier frequency. The repetition rate of this pulse pair 26 is typically 200 kHz and this may be amplified by means of amplifier 28 . The interrogator may also need to generate a timing or synchronising signal 30 which is sent to the AOM of the transmitter and also to the concentrator. The laser source 22 , AOM 24 and any amplifier 28 that may be present will normally be located on the platform or FPSO within the interrogator hub 20 . The arrangement includes an optical fibre 32 , preferably a single optical fibre, which forms part of the riser cable and extends from the platform or FPSO down to a concentrator located on the seabed in the region of the platform. In the concentrator are typically located a number of splitters, for example a 1:2 splitter 36 , 1:16 splitters 38 for each of the fibres from the splitter 36 and further 1:2 splitters 40 to split the optical fibre 32 into 64 fibres. The fibre may be split into any appropriate number of fibres, but will normally be split into 128 fibres or so. In addition, further amplifiers 42 , 44 may be present The optical signal may be amplified directly by means of an optical amplifier, for example an erbium doped fibre amplifier (EDFA). Any amplifier employed may also be a distributed optical amplifier which amplifies the optical signals continuously along part or the whole of the link between the interrogator and the array 1 .
The array comprises a two dimensional array of optical sensing units (OSUs) formed in each array line, and each sensing unit comprising three orthogonally oriented seismic vibration sensors and one hydrophone, the vibration sensors being typically separated by mirrors so that the delay and hence the phase change of signals reflected by the mirrors will depend on the parameter being detected by the OSUs. The sensors may also be connected in other configurations allowing measurement of individual sensor optical phase change.
After leaving the array the fibres return to the concentrator. Only a single fibre 50 is shown leaving the array line 1 for the sake of clarity as indeed only a single fibre 46 is shown entering the array, but as indicated above, typically 64 to 128 fibres will be employed. After leaving the array, the signals may be amplified by a further amplifier 52 (one for each optical fibre 50 leaving the array) which will typically be located inside the concentrator or may be located outside it if a distributed amplifier is employed. After amplification, the signal is passed to an optical-to-electrical converter typically comprising a detector formed from a p-i-n or avalanche photodiode 54 . The electrical signals so produced are sent to an A/D converter 56 to sample the signals, for example at 200 kHz, and to digitise them, and the digital signals are passed to a phase demodulator 58 . In one implementation, the signals will have a carrier frequency of 50 kHz, which is phase modulated by the seismic signal which will typically be in a frequency range of 5-500 Hz.
After phase demodulation, the signals from the optical fibre 50 together with the signals on all the other optical fibres 52 from the array are multiplexed by means of multiplexer 60 which also receives timing signals sent from the interrogator hub. As an alternative to sending timing signals directly to the receiver, timing signals sent to the array line by the transmitter may be detected before being sent to the array and then sent to the phase demodulator 58 by fibre 57 . The multiplexed signal is then converted to an optical signal by diode 62 or laser. The multiplexing may be performed electrically or optically or by a mixture of both and the signal on the fibre exiting the submersible module will preferably be wavelength division multiplexed (WDM) especially dense wavelength division multiplexed (DWDM) in which up to 128 signals may for example be carried by a single fibre on the 1550 nm band.
The DWDM signal is then carried by a single optical fibre 64 in the riser cable to the platform or FPSO whereupon it is converted to an electrical signal by means of photodetector 66 and sent to signal processing module 68 where the data is recorded and stored on disc 70 if necessary. Often the signal processing module 68 and disc or other recorder will be located physically close to one another in the same interrogator module or housing, but, as indicated above, the transmitter and receiver of the interrogator may be physically separated by a significant distance. Similarly, it is possible for different parts of the receiver to be separated between the concentrator and the interrogator hub. For example, it is possible for the receiver to include a communications module for packetising the multiplexed signals and sending them along a transmission channel to a recorder 70 as a single data stream, using techniques well known in digital data communications. The communications module may be operative to send the data from the demodulator 58 and multiplexer 60 by any appropriate means, for example by means of a satellite or microwave link, although it will normally be operative to send the data from the demodulator my means of a cable, especially an optical cable. This may be the same cable as the riser cable or a different cable.
For a typical array, the receiver will receive 16 time division multiplexed data streams each of which is converted into an electrical signal using a separate photodiode 54 . These are WDM multiplexed at 16 wavelengths, leading to 256 TDM data streams. The electrical data streams are digitised to generate 256 time domain multiplexed phase modulated outputs by the phase modulator 58 . In a typical heterodyne modulated system, each channel will have a heterodyne carrier frequency of 50 kHz and will be sampled at a sampling frequency of 200 kHz, although many other configurations of phase modulated data are possible. It will be necessary to multiplex the data at a rate sufficiently high to ensure that full bandwidth of the modulated data has been captured, so allowing accurate demodulation of the data. For example, in a typical system a data sample rate of 50 kHz with 32 bits per sample, 16 channels per wavelength and 16 different wavelengths will generate a signal with 0.4Gbits per second for each sensor line. If 64 sensor lines are employed as described above, this gives a total data transmission rate of 26 Gbits per second transmitted along fibre 64 . Clearly other data sample rates, or even data compression techniques may be chosen resulting in a different total data transmission rate.
The arrangement according to the invention thus enables the array 1 to be connected to the main part of the interrogator (the interrogator hub), i.e. those parts of significant size or which involve significant electronic signal processing, by only a small number of optical fibres so that conventional slip rings may be used, or even, depending on the form of packaging of the optical fibres, so that slip rings may be dispensed with and so that any change in direction of the fibre in the system may be accommodated by bending of the fibre. As described above with reference to FIG. 5 , the concentrator may be placed on the sea bed within a waterproof module requiring only a small number of fibre and power connections to the interrogator. The concentrator could include a stowed multi-way riser cable connecting the multiplexing optics and electronics to the array cables.
Such a form of concentrator is shown schematically in FIG. 7 . Here the interrogator is formed as a permanent installation 80 (which is the interrogator hub) on a platform 82 and includes a submersible module 84 (housing the concentrator) that is connected to the permanent installation 80 by the riser cable 9 comprising optical fibres 32 and 64 optionally together any electrical cables. The submersible module will house those parts of the interrogator which are located underwater, typically, the receiver demodulator and multiplexer, and also preferably parts of the transmitter as described above. The total volume of those parts of the interrogator within the submersible module will be of the order of 0.2 cubic meters, significantly smaller than the full interrogator which will have a volume of at least 3 cubic meters. The submersible module may include a reel or other means for stowing the riser cable that is able to collect the riser cable as the module is raised onto the platform 82 and to pay out any other cable if necessary connected to the array in order to accommodate the change in position of the module. Similarly the module may be arranged to pay out the riser cable 9 as it is lowered from the platform to the seabed and to collect any other cable attached to the array. The submersible module would normally be located on the seabed, although it could be used at any position in the water column.
It is possible in other instances to employ a multi-fibre riser cable with one fibre for each sensor unit of the array, and to locate the termination (including the phase demodulator and the multiplexer) on a stationary turret of an FPSO with single fibres directed to the interrogator unit on the main part of the FPSO by means of conventional slip rings. The termination that employs the submersible module could be employed with an FPSO if desired.
It is possible that more than 1 concentrator is used, as shown in FIG. 3 . In this case the individual concentrators 12 are each connected by a transmit optical fibre and a return datalink to the interrogator hub 11 via passive hub 16 which combines the individual transmit fibres and return fibres (if used) into a single riser 6 . Alternatively the concentrators 12 may be connected via a single cable arranged in a loop which connects all the concentrators to the passive hub. The loop may be arranged such that the signals can be transmitted in either direction around the loop
As described with respect to FIG. 5 , the sensor array sends phase modulated optical pulses whose phase modulation amplitude is dependent on the output of the sensors along the fibre 50 to the receiver. However, it is possible for the returned pulses to have too high a phase modulation amplitude and to cause phase based sensed information to become distorted leading to failure of the demodulation process. According to a preferred aspect of the invention, the sensors of the sensor array may be operable to generate derivative signals (that is, signals dependent on the rate of change of phase) instead of, or in addition to, the signals dependent on the amplitude of the phase. For example, this may be achieved as described in WO2008/110780, the disclosure of which is incorporated herein by reference. In this case, since two derivative signals are sent in addition to the phase amplitude signals, there will be approximately three data streams instead of one, and the system will require three times the bandwidth. The derivative return pulses (which are dependent on the rate of change of phase) will have a much lower phase modulation amplitude than the pulses that are dependent on the amplitude of the phase, and so may be used instead of the amplitude return pulses. In this case it is possible for the arrangement to have a much larger dynamic range by relying on high sensitivity amplitude return pulses where required and otherwise to rely on lower sensitivity derivative return pulses.
It is possible to vary the sensitivity of the return signals by varying the time separation of the initial signal and so increase the dynamic range of the system. In addition, as described in WO2010/023434, the disclosure of which is also incorporated herein by reference, the optical fibre that returns the signals from the sensors may be split so that light may be sent to two different interferometers that reflect the light along the return optical fibres 50 . One interferometer may have a relatively large path imbalance (say, 20 m or 200 ns) while the other interferometer may have a much smaller path imbalance (say, 1 m) which will be less than the pulse duration and will alter the dynamic value of the signal accordingly. As a result, it is possible for the derivative sensor technique to generate return pulses of a range of sensitivities, from high sensitivity return signals based on the amplitude of the reflected signals to medium and low sensitivity return signals based on the derivative of the phase of the reflected signals.
Although the derivative sensor technique may be used to generate return signals of three different sensitivities, different sensitivity signals for each of the different wavelengths in the WDM return signals may be carried by the same optical fibre. For example, one fibre may be used to carry medium sensitivity return signals (referred to as “long DST” signals, while another fibre may be used to carry full sensitivity and low sensitivity return signals (referred to as “normal” and “short” DST signals respectively.
The two fibres may extend in parallel to one another as shown in FIG. 6 . A single optical fibre 46 transmits the pulses from the transmitter 20 to a number of interferometers 5 in the concentrator which generates three signals, one medium sensitivity DST derivative output (referred to as the long output) on optical fibre 50 ( 1 ) and a full sensitivity amplitude output (referred to as the normal output) and a low sensitivity derivative output (referred to as the short output) that are multiplexed on optical fibre 50 ( 2 ). In this case each of the separate lines are converted into electrical signals, amplified where necessary, digitised with a 200 kHz sample rate, phase demodulated by phase demodulators 58 , and downsampled to a 1 kHz sample rate separately before being multiplexed with each other and with signals from the other OSUs in the array by multiplexer 60 . Timing signals that have been sent from the interrogator hub down the riser cable and received by the multiplexer 60 are sent to the phase demodulators 58 along lines 72 . In this arrangement, the phase delay between a 50 kHz synchronization signal and the incoming data will be computed at a data rate of 50 kHz. Data at approximately 1.5 Gbit s −1 from four array lines received by fibres 50 and 53 of FIG. 5 will be multiplexed by the multiplexer 60 to generate payload of 5.84 Gbit s −1 for each wavelength which can be transported by a 10 Gbit Ethernet line or other transmission protocol. The data from 16 lines is then multiplexed by multiplexer 61 by dense wavelength division multiplexing (DWDM) to allow data from 64 fibre pairs to be multiplexed on a single return fibre. | An arrangement for monitoring a submarine reservoir includes a number of sensor units located in an array on the seabed, and an interrogator unit for obtaining data on the reservoir from the sensor units. The interrogator unit includes a transmitter unit for sending optical signals to the sensor array and a receiver unit for receiving modulated optical signals from the array. Optical radiation from an optical source is transmitted along an uplink optical fiber which is split in a number of positions to form the array. The receiver unit includes optical-to-electrical converters for converting the optical signals to electrical signals, a phase demodulator, a multiplexer, a signal processor, and recording unit. The interrogator unit is divided into a concentrator and an interrogator hub, where signals are transmitted between the interrogator hub and concentrator along a riser cable. This enables the interrogator to be moved between a platform and the seabed. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a heald frame with a movable holding element fitted on a frame stave.
2. Description of the Prior Art
Guides, driving elements, etc. must be fitted on the frame staves of heald frames. This renders it desirable to fit holding elements at any desired positions over the length of the frame stave without having to do any machining thereon. Moreover, it is desirable to be able to move all the attached holding elements easily over the length of the frame stave and to fix them again effortlessly. Until now the holding elements were fitted on T-rails or T-shaped grooves on the outside edge of the frame staves. However, it has proved to be a disadvantage that, with this arrangement, the guides could be fitted only on the outside edge of the frame stave.
It would be advantageous if the guides could be extended over the side walls of the frame staves. Such types of guides have previously been manufactured, but they are usually fixed by means of glue on the frame staves. In that the guide is extended over the side walls of the frame stave and not only fitted at its outside edge, a sturdier and more reliable guiding of the complete heald frames towards each other can be achieved.
In many cases it is necessary to remove the guides from the heald frames. This can be due to lack of space on the drawing-in machine or for the purpose of cleaning the heald frames. Such removable guides, which extend over the side walls of the frame stave, are also known in the art. They embrace the frame stave and, on account of the fixing places for the plates of the heald carrying rods and the intermediate supports, can not be moved freely over the entire length of the frame staves. Especially on frame staves that form a complete unit together with the heald carrying rods, such guides cannot be fixed because they embrace the frame staves and, therefore, hinder the moveability of the healds.
SUMMARY OF THE INVENTION
It is a principle object of the present invention to eliminate the disadvantages of known heald frames and to create a holding element which can be shifted unhindered over the entire length of the frame stave and which can be fitted at any position of the heald frame stave.
The invention fullfils this objective in that each frame stave is provided with ribs pointing towards the center of the heald frame which run over the entire length of the frame stave. The holding element is provided with groove shaped parts which grip the ribs and with a clamping device in order to secure the holding element on the frame stave.
In a preferred embodiment guide plates are connected to each other by means of at least one distance plate. The guide plates grip the frame staves at both sides and rest on either side wall of the frame stave. The free edges of the guide plates are bent and point towards the center of the heald frame.
The securing device can be loosened by means of screws which are easily accessible from outside the frame stave. The screws can, for example, press a spring device or a pressure element towards the outer small edge of the frame stave. If a spring device is used, the screw can be fitted in such a way that the screw head rests on a firm stop so that the pressure is always the same and will not cause an overstressing of the securing parts.
It will also be possible to provide a holding element with engaging parts for the connecting of a heald frame onto the driving element of the weaving machine which additionally will also serve as a guide for the neighboring heald frame.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 shows a heald frame with two holding elements fitted on the upper frame stave and three holding elements fitted on the lower frame stave.
FIG. 2 shows a front view of a guide fitted on the frame stave,
FIG. 3 shows a side view of the guide according to FIG. 2,
FIGS. 4 through 6 show various embodiments of frame staves in cross section,
FIG. 7 shows a further embodiment of a frame stave,
FIG. 8 shows a cross section through lines VIII--VIII in FIG. 7,
FIG. 9 shows a front view of a holding element with a driving bush fitted on a frame stave, and
FIG. 10 shows a side section of a holding element according to FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a complete heald frame including an upper frame stave 1 and a lower frame stave 1'. On the respective heald carrying rods 2, 2' healds 3 are lined up. Both frame staves 1, 1' are connected by means of lateral supports 4. On the upper frame stave there are two holding elements 5 serving as guides, on the lower stave one holding element 5 serving as guide and two holding elements 26 with driving bushes 27.
FIGS. 2 and 3 show how the guides 5 are fitted on the frame stave 1. Guiding plates 6 and 7 are connected by means of distance plates 8, 9 which, for example, can be glued in. The bent parts 10, 11 of the guiding plates 6, 7 which point towards the center of the frame, grip ribs 12, 13 which are arranged on both sides of the frame stave 1. To achieve favorable gliding behavior one or both of the guiding plates 6, 7 can be covered by an abrasion proof gliding layer 14, 15 made, for example, of wood or plastic. To secure the guide 5 in the required position on the frame stave 1 a screw 16 can be inserted from above through a gap 17 formed by the two distance plates 8, 9 into a threaded plate 18. The width of this threaded plate corresponds to the thickness of the frame stave and the thickness of the distance plates 8, 9 respectively, and both ends of the threaded plate are inserted in the distance plates 8, 9 in the longitudinal direction of the frame stave 1 and thus are immovably connected with the guide 5. The lower free part 19 of the screw 16 which points towards the small edge 20 of the frame stave 1 presses on an oval shaped leaf spring 21 which is inserted between the frame stave 1 and the distance plates 8, 9. The pressure is determined by the strength and the elasticity characteristics of the leaf spring 21. The screw 16 is always completely screwed into the threaded plate 18 so that the screw head 22 rests on it.
Both the guiding plates 6, 7 and gliding layers 14, 15 are preferably provided with openings 23, 24 which permit checking whether the screw is tight or loose. In order to remove the guide 5 the screw 16 must be loosened to the extent that the pressure on the leaf spring 21 is released and then additionally loosened as much as the depth of the bent portions 10, 11 on the plates 6, 7. This assures that the guiding plates 6, 7 can be lifted over the ribs 12, 13 of the frame stave 1 and thus enables the removal of the guide 5.
FIGS. 3 - 6, 8 and 10 show different configurations of the frame stave 1 provided with ribs 12, 13 for the purpose of hanging in the holding elements.
The rectangularly shaped hollow profile 1 is provided with a protrusion 31 opposite of the outer edge, 20. The extensions of the side walls of the frame stave 1 pointing towards the center of the heald frame are formed as ribs 12, 13.
In the embodiments of FIGS. 3 and 10 one of the extensions of the side walls serves simultaneously as protrusion 31 at whose end, besides the heald carrying rod 2, a rib 13 is also provided. The ribs 12, 13 which are arranged on both sides of the frame stave 1 can be arranged opposite each other or can be relatively displaced towards the center of the heald frame.
There is a possibility that during the weaving process, within the region of the ribs 12, 13 especially at the lower frame stave 1', fluff and dirt may get caught which, in the course of time, will hinder the healds 3 in their movability. FIGS. 7 and 8 show how ribs 12, 13 can be provided with recessions 25 the distances of which correspond to the widths of the shaft guides 5. Fluff which accumulates behind the ribs 12, 13 can drop out with this configuration.
FIGS. 9 and 10 show an arrangement for fixing a holding element 26 with a driving bush 27 on to the frame stave 1. To secure the holding element 26 a pressure element 28 is inserted between the two guide plates 6, 7 and pressed onto the outer edge 20 of the frame stave 1 by means of two screws 29 which are inserted through the distance plate 30. The guiding plates 6, 7 can also be provided with abrasion proof glide layers 14, 15 if this will serve for a better guidance of the heald frame at the position where the holding element 26 is fixed. | The frame staves (1, 1') of a heald frame have ribs (12, 13) on opposite sides of the stave extending toward the center of the frame. Movable holding elements (5, 26) on the staves include guide plates (6, 7) extending over the sides of the staves and having inbent edges (10, 11) that grip the ribs. The holding elements are drawn up against the staves by screw and spring arrangements. | 3 |
BACKGROUND OF THE INVENTION
[0001] This invention relates generally to garage door openers. More particularly, this invention relates to a soft start motor for a garage door opener.
[0002] Various types of automatic garage door openers have existed for many years. Conventional automatic garage door openers are electromechanical devices which raise and lower a garage door to unblock and block a garage door opening in response to actuating signals. The signals are electrical signals transmitted by closure of a push-button switch through electrical wires or by radio frequency from a battery-operated, remote controlled actuating unit. In either case the electrical signals initiate movement of the garage door from the opposite condition in which it resides. That is, if the garage door is open, the actuating signal closes it. Alternatively, when the garage door is closed, the actuating signal will open the garage door. Once movement has been initiated, the system is deactuated when the garage door movement trips a limit switch as the garage door approaches its open or closed position.
[0003] Conventional drive systems typically include either a very long worm drive or a very long drive through a chain loop tensioned between a pair of sprockets. The chain is connected to the garage door. A typical worm drive shaft is at least about eight feet in length, while the sprockets in a chain loop drive are likewise separated by a distance of at least eight feet.
[0004] When a conventional motor is activated, an instantaneously high current is usually generated. This high locked rotor torque creates high stresses on the mechanical linkages as the reverse direction play is slammed out. One of the main limiters to life of a garage door opener and its hardware is this impulse, which strikes the mechanical components of the door opener with large locked rotor torque to help break away door under frozen conditions. This impulse is applied in all conditions whether needed or not. Such motor hard start further creates distracting noise. Therefore, there is a need for an improved garage door opener.
SUMMARY OF THE INVENTION
[0005] As described herein, embodiments of the invention overcome one or more of the above or other disadvantages known in the art.
[0006] In one aspect, the invention relates generally to a garage door opener. The garage door opener has a user interface and a motor operatively connected to the garage door, at least one sensor, and an integrated motor control circuit. The integrated motor control circuit has a motor control microprocessor and a memory. The memory contains previous operation data. The motor control microprocessor receives data from the user interface, the memory and the sensors to control the motor.
[0007] In another aspect, a garage door opener is disclosed. The garage door opener has a user interface, an integrated motor control circuit at least one sensor, and a motor. The integrated motor control circuit has an alternating current to direct current converter, a motor control microprocessor, an inverter, and a memory. The memory contains previous operation data. The sensor provides current operation data to the motor control microprocessor. The motor is in communication with the motor control circuit and is operatively connected to the garage door. The motor control microprocessor receives data from the user interface, the memory and the sensors to control the motor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The following figures illustrate examples of embodiments of the invention. In the drawings:
[0009] FIG. 1 is a perspective view of a garage door opener.
[0010] FIG. 2 is a schematic representation of an aspect of the invention integrated into the garage door opener of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0011] While the apparatus herein is described in the context of a garage door opener, as set forth more fully below, it is contemplated that the described apparatus or method may find utility in other applications. The description herein below is therefore set forth only by way of illustration rather than limitation, and is not intended to limit the practice of the herein described methods and apparatus.
[0012] FIG. 1 illustrates a garage door opener 114 as is known in the art. Garage door opener 114 is mounted on the ceiling 112 of a garage and with a garage door 110 movably mounted on rails 121 and 122 . A shaft 108 is rotatably mounted above the door 110 on the wall 107 and carries counter balance spring 123 . Cables and pulleys such as the pulleys 105 and 106 are attached to the shaft 108 and the cables are connected to the door so as to spring bias it to counter balance the weight of the door in a conventional manner. The garage door opener 114 is attached to the ceiling 112 by bracket arms 117 and 118 which have portions 119 and 120 through which openings are formed to attach the door operator to the ceiling 112 .
[0013] The garage door operator has a main body portion 113 which may have a light 116 . The motor, gear train and various electrical components are contained in the body compartment 113 . A rail 128 extends from the body portion 113 and may be formed in a number of tubular sections which telescope together for support of a chain drive or other similar system or may be a treaded rod for a worm drive or similar system for opening and closing the garage door. A trolley 127 fits over the tubular rail 128 and has an arm 124 of generally L-shape which is attached to the trolley. The other end of the arm 124 is attached to a bracket 6 connected to the door 110 such that as the trolley 127 is moved relative to the rail 128 , the door can be opened and closed.
[0014] According to an aspect of the invention, as shown in FIG. 2 , the main body houses the controls and operating components of the system. Line power 250 , such as but not limited to 110V or 240V alternating current or AC, is supplied to the system and converted to a direct current or DC voltage in AC to DC converter 210 . DC bus 252 supplies the operating power to the integrated motor control circuit 201 .
[0015] When a user actuates user interface 230 a signal is sent via bus 202 to the opener microprocessor control board 220 to direct the motor control microprocessor 204 on integrated motor control circuit 201 via bus 258 . User interface 230 may be a remote device such as a RF remote or button or switch, or may be a human machine interface, HMI, for user control and display of system information to the user. Motor control microprocessor 204 provides a start signal to inverter 208 via bus 262 . The start signal may be preprogrammed or when data is available the start signal may be provided from a memory profile 212 via bus 264 .
[0016] Memory 212 contains data from previous operation of the garage door opener 114 . The data stored may include, but is not limited to, operating temperature of the motor, ambient temperature, rotor speed or torque. The use of the memory profile data permits the motor control microprocessor to adjust the start signal depending on the ambient conditions. The conditions may include, door hard start, such as where the door has iced to the floor 111 , operating torque, such as excess friction or during the vertical traverse as opposed to the horizontal traverse. The motor control microprocessor 204 may also utilize present operation parameters, such as the current draw of the inverter 208 via bus 254 , rotor speed 216 via bus 256 . These parameters are used to monitor garage door operation such as torque demand, sudden changes in torque demand and communicate this information back to the main control board to allow for condition diagnosis.
[0017] The motor control microprocessor 204 of the variable speed motor 206 may determine trends in operating torques and self learn speed profiles based on the rotor revolutions to match each individual garage door application. This would allow each application to develop on its own a unique profile based upon recorded data during operation to match motor operation parameters to individual needs. Things like ramp up and down rates and torques could be self taught and optimized based on self learned parameters.
[0018] The variable speed motor 206 may be a three phase motor or any other variable speed AC or DC motor. The information relayed from the motor control to the garage door opener main board could include torque, long and short term changes in torque demand for operation, and could be used for sensing broken springs, or maintenance requirements. This information may be used to assist service requirements or determine correct operation of the variable speed motor. Further, by utilizing feedback from the sensors, the torque of the motor may be incrementally increased during the start of the garage door opener until a predetermined operation speed of the motor is obtained. By incrementally increasing the torque during motor start excess noise and wear on mechanical parts will be prevented, increasing customer satisfaction and increasing reliability of the garage door opener.
[0019] A visual signal, such as a flashing light emitting diode or LED, to relay health status or serial communication status. The visual signal may also be an auditable signal or a display on an HMI device.
[0020] While the invention has been described in terms of a specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims in similar applications. | This invention relates generally to a garage door opener. The garage door opener has a user interface and a motor operatively connected to the garage door, at least one sensor, and an integrated motor control circuit. The integrated motor control circuit has a motor control microprocessor and a memory. The memory contains previous operation data. The motor control microprocessor receives data from the user interface, the memory and the sensors to control the motor. | 4 |
[0001] This application claims priority under 35 U.S.C. §119(e) from U.S. Provisional Patent Application No. 62/353,162 for a PIVOT COUPLING FOR CONTAINMENT PLOWS AND PUSHERS, by M. Guggino et al, filed Jun. 22, 2016, which is hereby incorporated by reference in its entirety.
[0002] The embodiments disclosed herein are directed to an improved, simplified coupling that permits the use of material pushers, containment plows (e.g., snow pushers) and similar attachable equipment with a variety of vehicles that can be used to move equipment such as plows/pushers, including all-terrain vehicles (ATVs), utility task vehicle (UTV), lawn & garden tractors, small farm tractors, small trucks, skid-steer loaders, etc.
BACKGROUND AND SUMMARY
[0003] Conventional snow pushers and similar containment plows have, for the most part, been designed for use with large vehicles such as loaders, backhoes and similar heavy-duty equipment that have buckets or other standard coupling mechanisms to allow the vehicle to be easily attached to the containment plow. As containment plows are becoming more accepted for plowing, cleaning and maintaining smaller areas, or areas that cannot withstand the weight of heavy equipment (e.g., turf football fields, feed lots, bladder-lined reservoirs, etc.), a need has been recognized to easily fit such containment plows and similar attachable equipment to smaller vehicles. However, an impediment to simply putting a containment plow on the front of an ATV or a UTV, as that such vehicles have different coupling mechanisms, and require customizations in order to work with conventional couplers used on such plow/pushers. Moreover, some vehicles lack or have limited ability to raise and lower a plow attached to the front of the vehicle, let alone adjust the angle of tilt of the plow relative to a surface being plowed.
[0004] Recognizing a need to provide improved connect-ability for containment plows, material pushers and the like, the various embodiments described herein seek to “standardize” the containment plow with a simple pivoting attachment mechanism, and thereby enabling use of such equipment by only altering the vehicle interface in order to fit the same plow, or same plow model to different vehicles. In doing so, customized couplers have been designed to fit a range of different vehicles and the couplers each have a plow interface that is common, including a pivoting connection to allow the plow/pusher to “ride” over surface changes while still providing a tilt-angle limiting feature. The plow interface provides for easy separation of the plow from the coupler by removal of a pivot pin(s). Moreover, the ease of coupling/uncoupling the plow allows for multiple vehicles to be fit with a coupler which allows a plow outfitted with the coupling to be used interchangeably with several vehicles.
[0005] Disclosed in embodiments herein is a material pusher coupling system, comprising: a material pusher having a pair of spaced-apart hinge bosses (knuckles) attached to a rear of the pusher and located along a common axis parallel with the longitudinal axis of the material pusher; a vehicle coupler including a pusher interface on one side thereof and a vehicle interface on another side thereof, where the pusher interface includes at least one hinge boss fitting between the spaced apart hinge bosses in a position where a common hinge pin extends through the interior of the spaced-apart hinge bosses and the at least one hinge boss, so as to cause the material pusher and the vehicle coupler to be in a pivoting, hinged connection to one another; and wherein the vehicle interface is suitable for attachment to structural components of the vehicle to which the material pusher is to be attached for use.
[0006] Also disclosed in embodiments herein is an equipment coupling system, comprising: an attachable piece of equipment having a pair of spaced-apart hinge bosses attached to a rear thereof, the hinge bosses being located along a common axis, said axis being parallel with a longitudinal axis of the piece of equipment; a vehicle coupler including an equipment interface on one side thereof and a vehicle interface on another side thereof, where the equipment interface includes at least one hinge boss, fitting between the spaced apart hinge bosses, in a position where a common hinge pin extends through the interior of the spaced-apart hinge bosses and the at least one hinge boss on the vehicle coupler, to cause the piece of equipment and the vehicle coupler to be in a pivoting, hinged connection to one another; and wherein the vehicle interface is suitable for attachment to components of the vehicle to which the piece of equipment is to be attached for use.
[0007] Further disclosed in embodiments herein is an alternative embodiment where pins are employed for the connection of equipment to vehicles, for example, an equipment coupling system, comprising: an attachable piece of equipment having at least one pair of spaced-apart first bosses attached to a rear thereof, each pair of first bosses being located and aligned along a common axis, said axis being parallel with a longitudinal axis of the piece of equipment; a vehicle coupler including an equipment interface on one side thereof and a vehicle interface on another side thereof, where the equipment interface includes at least one pair of second bosses for each of the first bosses on the attachable piece of equipment, wherein for each of said first bosses and associated pair of second bosses a common pin extends through the interior of the first boss and pair of second bosses on the ends thereof to cause the piece of equipment and the vehicle coupler to be connected to one another; and wherein the vehicle interface is suitable for attachment to components of the vehicle to which the piece of equipment is to be attached for use.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIGS. 1-3 illustrate components of a material pusher (e.g., a turf pusher) and an associated coupler in accordance with a disclosed embodiment;
[0009] FIG. 4 is an exemplary illustration of the pivot coupling system with a “dummy” coupler;
[0010] FIG. 5 is a side view of an exemplary embodiment of the coupling system;
[0011] FIGS. 6A and 6B are illustrative examples of alternative couplers from the vehicle side;
[0012] FIG. 7 is an illustrative example of an alternative coupler from the plow side; and
[0013] FIGS. 8A and 8B are perspective views of an alternative coupling system embodiment.
[0014] The various embodiments described herein are not intended to limit the disclosure to those embodiments described. On the contrary, the intent is to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the various embodiments and equivalents set forth. For a general understanding, reference is made to the drawings. In the drawings, like references have been used throughout to designate identical or similar elements. It is also noted that the drawings may not have been drawn to scale and that certain regions may have been purposely drawn disproportionately so that the features and aspects could be properly depicted.
DETAILED DESCRIPTION
[0015] Referring to the figures, depicted therein are various embodiment of the disclosed pivoting coupling system. For example, in FIGS. 1-3 , there is shown a material pusher coupling system 100 . The system includes a piece of equipment such as a material pusher 90 having a pair of spaced-apart hinge bosses 110 (also referred to as hinge knuckles) attached to a rear surface or structure 94 of the pusher and located along a common axis 120 , parallel with the longitudinal axis of the material pusher. Also included is a vehicle coupler 160 including a pusher interface on one side thereof and a vehicle interface on another side thereof, where the pusher interface side includes at least one hinge boss 162 designed to fit in-between the spaced apart hinge bosses in a position where a common hinge pin 180 extends through the interior of the spaced-apart hinge bosses and the at least one hinge boss on the coupler, thereby causing the material pusher and the vehicle coupler to be in a pivoting or hinged connection to one another. And, as illustrated, for example, in FIG. 5 , the vehicle interface is suitable for attachment to structural components of the vehicle 210 to which the material pusher is to be attached for use.
[0016] As illustrated in FIGS. 2-3, 5 and 7 , the pusher interface or coupler 160 may include an angular limit device(s) 168 in the form of a block, weldment, or possibly even a deformable material, attached to the front of the interface adjacent the hinge boss 162 —in one embodiment the angular limits 168 are attached on and parallel with either side of the boss itself. The angular limit 168 is intended to control the relative amount of pivot (rotation) of the material pusher 90 with respect to the vehicle 210 .
[0017] Referring to FIGS. 6A and 6B , these figures, respectively, illustrate examples of alternative coupling systems 100 , or more particularly vehicle coupler 160 for both Avant Tecno and Steiner tractors. In the case of coupler 160 in FIG. 6A , the vehicle side is similar to the known adapter plate (e.g., Part No. A2471 from AVANT TECNO USA Inc.) and includes a pair of attachment hooks 610 at the top of plate 612 , and a foot 614 beneath the hooks, the foot having a hole for receiving a locking pin from the Avant machine to lock the adaptor in place. The vehicle coupler 160 for the Steiner vehicle has a vehicle interface similar in design to a Steiner Quick-Hitch™ System, and is illustrated in FIG. 6B , formed as a generally horizontally-oriented component that includes, on each side thereof a U-shaped receiver 640 on each end of adaptor 642 , and holes 644 through which a locking pin(s) 646 may be placed to lock the adaptor to the tractor (not shown). FIG. 7 is an example of an alternative coupler 160 that is designed for a Toro tractor, and is shown from the plow or attachment side.
[0018] As will be further appreciated, while the amount of pivot about the hinge pin 180 is limited by the potential contact of the coupler and the plow, the addition of the angular limit devices 168 may be customized for particular couplers to match the capability of the vehicle. For example, a vehicle having the coupler attached directly to its frame or to a limited-lift structure would only have a small amount of permitted pivot range (arrow 190 ), whereas a vehicle (e.g., 210 ) having the ability to significantly raise/lower a plow, snow blower, bucket, etc., may have a greater pivot range to permit more flexibility in the use of the plow, for example, over uneven surfaces. Thus, the relative amount of pivot (e.g., rotation about axis 120 ) for a particular coupling system is dependent upon or a function of the vehicle's configuration or capability.
[0019] While in general practice the angular limit 168 would be placed on the coupler interface so that it may be customized to the vehicle as described above, it is contemplated that in an alternative embodiment the rear surface of the material pusher has the angular limit installed to control the relative amount of pivot (rotation) of the material pusher with respect to the vehicle. Also contemplated is the use of an adjustable angular limit device or configuration, where a surface of the limit device can be adjusted, or replaced with a device of different size in order to modify the pivot range.
[0020] As noted, the coupling to a vehicle is completed by insertion of a hinge pin 180 through the middle of the hinge bosses attached to the plow and the coupler, with the hinge pin spanning at least a combined length of the bosses. Preferably the hinge pin outer diameter is just slightly smaller than the diameter of the hinge bosses (e.g., from 0.5″-1.5″ in diameter) and the pin extends slightly beyond the end of the outermost bosses, and also includes through holes in it that enable the use of a washer(s) and a locking mechanism such as a spring-type linch pin 194 to be placed through it in order to retain the hinge pin in place once the coupling is completed.
[0021] Turning now to FIGS. 8A-8B , depicted therein is an alternative embodiment of the coupling system 100 that employs multiple pins 180 and associated bosses 110 placed at several locations on the rear of the pusher 90 or similar equipment attachment. In the illustrated embodiment, several options are available for attachment and use of the equipment coupling system. For the first option, the spaced-apart first bosses 110 a on the rear surface 94 of the snow pusher 90 are spread out to provide more stability to the coupling system. The attachment has, for at least several of the first bosses 110 a a pair of second bosses 110 b on the face of the coupler that “sandwich” or surround at least a pair of the first bosses 110 a . In this first option, two of either the upper or lower pair of first bosses 110 a may be pinned to the coupler 160 to provide the hinged coupling in a manner equivalent to the discussion above—but with shorter pins 180 , permitting ease of attachment and detachment.
[0022] In the second option, each of the spaced-apart first bosses 110 a on the attachable piece of equipment, such as pusher 90 , is located and aligned along a common axis (e.g., axis 120 ), the axis being parallel with a longitudinal axis of the piece of equipment. The vehicle coupler 160 , includes the equipment interface on the equipment-facing or front side thereof in FIG. 8B , and a vehicle interface on the vehicle-facing or rear side thereof, and the equipment interface includes at least one pair of second bosses 110 b for several or each of the first bosses 110 a on the rear of equipment. Moreover, each of the first bosses and associated pair of second bosses has a common-sized pin extending through them to connect the first and second bosses, and to thereby cause the piece of equipment and the vehicle coupler to be connected to one another. In the illustration of FIG. 8B , if all four pins 180 are employed, the coupler provides for a non-pivoting attachment of the equipment to the vehicle—which may be preferable in certain vehicle and equipment use configurations (e.g., where the vehicle itself includes an adjustable-angle attachment that allows an operator to change or control the angle of the equipment when it is attached for use). As will be appreciated from a review of FIG. 8A , each of the first bosses 110 a further includes a reinforcement 98 so as to spread the load applied to the first boss during use over a larger portion or structure of the pusher rear surface 94 .
[0023] It should be understood that various changes and modifications to the embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present disclosure and without diminishing its intended advantages. It is therefore anticipated that all such changes and modifications be covered by the instant application. | A pivot coupling system that permits the use of attachable equipment such as material pushers or containment plows with a range of vehicles including all-terrain vehicles (ATVs), utility task vehicle (UTV), lawn and garden tractors, small farm tractors, small trucks, skid-steer loaders, etc. | 4 |
[0001] This application is a continuation-in-part of Applicant's co-pending application U.S Ser. No. 09/195,781, filed Nov. 18, 1998 and titled Video Teleconferencing Assembly and Process, which application is pending, and which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to video teleconferencing assemblies and processes and more particularly to video teleconferencing assemblies and processes relating to medical, analytical and research applications. The video teleconferencing assemblies and processes relate to computer based services in present time and which include training, diagnostic and repair services for medical equipment as well as to laboratory procedures. The assemblies and processes of the invention further relate to the repair, installation, calibration and operation at remote sites of equipment in other industries, for example, industrial machines, tools and equipment, industrial process equipment, telecommunication equipment, heavy construction equipment, agriculture, food processing, food service, electronic and packaging equipment and heating, vacuum and air conditioning equipment and the like.
[0003] The assemblies of this invention include a host site and a remote site and between which information is relayed via a telecommunication link, such as via the internet, satellite point to point relay, satellite network relay, electromagnetic (EM) wave transmission, graviton radiation wave transmission or via radio frequency (RF) wave transmission, for example. The invention relates particularly to video duplexing (i.e., receiving and sending information concurrently) and is adapted to provide diagnostic services for servicing various research devices, medical equipment and related processes, for example.
[0004] Presently, if equipment located at a remote area fails to perform properly, needs servicing, or is scheduled to be tested, a service technician, skilled in a particular art, is often required to travel to that remote location to diagnose the problem, order the parts, and repair and test the equipment. Travel and time considerations make this practice an expensive and time consuming procedure. The assembly and process of this invention overcome these problems and shortcomings and does so in a timely and efficient manner.
[0005] The present invention permits a party, such as an operator located at a host site, to directly communicate with a second party at a remote location via a telecommunication link. The telecommunications link may comprise a telephone line, a data line, a satellite connection, the internet, wireless communication, satellite point to point direct relay, satellite network relay, electromagnetic wave transmission, graviton radiation wave transmission, radio frequency wave transmission and other communication links and combinations thereof. This invention also permits multiple parties at both the host and remote sites to be in direct communication with each other.
[0006] The present invention includes the adaptation of a visual and audio recognition system in the medical application at the remote site. The visual and/or audio recognition systems are used with medical apparatus and laboratory procedures at the remote site. The recognition system is monitored at the host site. The apparatus may include or be connected to a modem so that data may be directly sent to the host site for monitoring and diagnostic purposes.
[0007] The assemblies and processes of this invention permit various services and procedures to be performed between two separated or distant sites. These services include: technical and application troubleshooting, instrument installation assistance, technique monitoring and training, and technical training. Further, this invention may be used for parts replacement assistance, instrument and parts identification, instrument performance verification, staff monitoring, client and staff counseling, and enhancement of sales and service capabilities. Examples of areas in which this assembly can be used include: diagnosing instrument malfunctions, determining misalignment and movement impairments for robotics applications, monitoring fluidic action in medical applications, diagnosing pressure or vacuum malfunctions and mechanical impairments, diagnosing and adjusting electronic circuitry, and diagnosing technical malfunctions of chemical reactions and dilution ratios.
[0008] An object of this invention is to provide to industrial, research and medical institutions as well as to industrial machine, tool and equipment, industrial process equipment, telecommunication equipment, heavy construction equipment, agriculture, food processing, food service, electronic and packaging equipment, and HVAC equipment entities, and the like, assemblies and processes adapted for dealing with various service applications. For example, the repair, installation, calibration, monitoring and operation of equipment, devices and processes in various industries may be serviced by the assemblies and processes of the present invention. Preferably, the technical service is available on a 24 hours per day basis. A medical application for the purposes of this invention includes medical apparatus and laboratory procedures. For example, medical instrumentation having robotic equipment, vacuum or pressurized fluid holding components, electronic circuitry, or chemical components or consumables may be monitored by the assembly and process of the invention.
[0009] Medical equipment areas and products within those areas for which the assembly and process of this invention may be used, include but are not limited to: Medical Products including cardiac monitors, gamma counters, lasers, peptide synthesizers, autoclaves, EKG, imaging equipment, operating tables, portable X-ray's, and the like; Research/Production products including atomic absorption, DNA extractors, DNA synthesizers, flow cytometers, freeze dryers, gamma counters, HPLC, mass spectrometers, microtomes, peptide synthesizers, autoclaves, cell counters, centrifuges, fermenters, LS counters, microplate readers, pilot plant equipment, RIA analyzers, and the like; Analytical products including atomic absorption, DNA extractors, DNA synthesizers, flow cyometers, freeze dryers, gamma counters, HPLC, mass spectrometers, microtomes, peptide synthesizers, autoclaves, cell counters, centrifuges, fermenters, LS counters, microplate readers, RIA analyzers, and the like; and General Laboratory Medical products including chemistry analyzers, coag analyzers, DNA extractors, DNA synthesizers, electrolyte analyzers, flow cytometers, gamma counters, HPLC, microtomes, autoclaves, blood gas analyzers, cell counters, centrifuges, densitometers, LS counters, RIA analyzers, imaging and radiology products and the like. The latter products and equipment including those having a c.p.u. and related peripheral computer devices, i.e., a modem, being exemplary, however, and other equipment in other fields may also be serviced according to the teachings of the present invention. The assembly and process of this invention can be used to analyze not only research and medical device problems, but may also include the chemicals (consumables and reagents) that are used to generate the test results for patients and which are used for quality assurance purposes.
SUMMARY OF THE INVENTION
[0010] This invention relates to video teleconferencing assemblies and processes between separated sites or distant physical locations for the purpose of providing particular services related to medical applications in present time. The invention includes a host site and a remote site and wherein specified equipment is located at each site for communication between the sites.
[0011] The host site assembly includes a computer, video and audio hardware and a communication link between the host and remote sites, such as via an internet connection, a satellite point to point direct relay, satellite network relay, electromagnetic wave transmission, graviton radiation wave transmission, radio frequency wave transmission and like communication connections. The computer preferably contains PCI bus architecture. Specific hardware and software are also used for video duplexing including a video input device, such as a camera in addition to a PCI video digitizing card. Finally, the invention may require an internet connection consisting of internet related hardware, software and services. The internet connection preferably uses an ISDN router/hub, DSL, cable modem, T-1000 or the like, a communications link such as an analog or digital telephone line, a network providing internet connectivity, and an internet service provider. The communication link utilized for the internet connection may include ISDN, T-1000, a satellite transmission, digital and analog lines, or the like. The communication link may also include lines having combinations of these connections. As discussed, the communication link may be established via satellite point to point direct relay, satellite network relay, electromagnetic wave transmission, graviton radiation wave transmission, radio frequency wave transmission and/or other communication connections which provide for the transmission of data, video and audio signals.
[0012] The host site further has reference materials relating to medical applications that are located and used at a remote site. The reference materials include information relating to various medical applications including medical apparatus and medical testing procedures used in medical laboratories. The medical applications are provided with visual and/or audio recognition systems that are recognized and analyzed at the host site.
[0013] The remote site assembly includes a computer, video and audio hardware, an internet connection or other communication link, such as a satellite direct relay or other transmission. Preferably, the remote site assembly is portable to enable setup of the assembly in proximity to the device or process that is the subject of the conferencing session. The video hardware also includes a portable video input device. The computer and internet connection or other communication is similar to and compatible with that of the host site.
[0014] The process of this invention involves the utilization of the computer assemblies located at the host and remote sites and includes a number of process steps. To conduct a video conferencing session, the host site is initially turned on and connected to the internet or to another communication link, such as satellite point to point direct relay, satellite network relay, electromagnetic wave, graviton radiation wave transmission or radio frequency wave transmission. The host system may identify the IP address and utilizes an operational video capture subsystem to perform video duplexing. Communication may be received in video and/or audio and carried out by informing the remote site assembly of the IP address of the receiving computer located at the remote site.
[0015] The computer assembly at the remote site includes an internet connection or the like via an ISP connection and/or means to establish a communication link via satellite point to point direct relay, satellite network relay or other transmission. Users may send calls to the host site's IP address by means of video and/or audio. Communication between the remote site and the host site is maintained via communication software, such as Netmeeting 2.0 or like software, for example.
[0016] The visual and/or audio recognition systems of the invention include visual indicators used in connection with medical apparatus and laboratory procedures. The visual and/or audio indicators are used to determine the status of medical applications at the remote site. A modem may also be connected to or incorporated into the medical application for transmitting data and/or other signals between the host and remote sites. For example, the visual indicators may include a plurality of colored lights, such as LED's. The visual and/or audio recognition systems may be internal or external to the medical apparatus.
[0017] These and other benefits of this invention will become clear from the following description by reference to the drawing.
DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a schematic diagram showing the host site and the remote site as well as the equipment utilized at the respective sites;
[0019] [0019]FIG. 2 is a schematic diagram showing the steps utilized between the host site and remote site(s) to practice the present invention;
[0020] [0020]FIG. 3 is a schematic diagram showing a satellite point to point direct relay between the host site and the remote site; and
[0021] [0021]FIG. 4 is a schematic diagram showing a satellite network relay between the host site and the remote site.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] As shown in FIG. 1 of the drawing, a schematic diagram is set forth showing the assemblies utilized in the present invention. FIG. 1 shows the host site and the remote site connected for communication, such as via the internet, via satellite point to point direct relay, via satellite network relay, via electromagnetic wave transmission, graviton radiation wave transmission or radio frequency wave transmission. The respective sites may be located in different countries for example, whereby an operator having access to various manuals and databases is able to communicate with a technician at the remote site. The communication between the host site and the remote site may be in present time, i.e., at least 30 frames /sec., however, this communication speed is not required for purposes of this invention. For example, communication between the sites at 15 frames per/sec. has been found suitable for purposes of practicing the teachings of this invention. The operator at the host site, in the U.S.A., for example, is able to communicate with a technician at a hospital or other person at a remote facility, in either the U.S.A. or in a country outside of the U.S.A. for example, and is able to instruct the technician to diagnose and repair a particular piece of equipment, for example. Initially, a business relationship may be entered into between the respective parties by means of an agreement sent via facsimile.
[0023] For example, it is customary and important under the laws and governmental regulations of various countries that proper agreements and service procedures be followed with respect to the servicing of specified equipment. The computer assemblies of this invention may include databases having specified contracts for service orders, for example. The operator at the host site may transmit the proper documentation to the remote site for signature and subsequently have the signed agreement of service order returned to the host site so that a contractual relationship has been entered into before any substantive services are provided.
[0024] [0024]FIG. 1 further shows that the operator at the host site has available for use various equipment, manuals, references, databases and a visual recognition system for performing the various services set forth herein. For example, the operator upon seeing the equipment at the remote site may consult an equipment manual, access a database and provide service information to the technician at the remote site or to other individual parties at the site. The verbal and visual information exchanged between the sites may include the use of similar operational devices, teaching aids and programmed procedural techniques at the host site so that the technician at the remote site may readily see and understand the proper operational parameters of the equipment or procedure at issue.
[0025] The assembly and process of the invention include the use of a visual and/or audio recognition system. A visual recognition system is a visual signal provided by a medical application located at the remote site that indicates to a host site technician a particular problem or the general condition of the device or process. The visual signal provided is such that the host site technician, for example, can easily identify it via the video teleconferencing system. The visual recognition systems may include a light or a plurality of lights which when activated relate to a specific condition. Further, a light or plurality of lights may flash in predetermined patterns to show the status of medical equipment. The visual recognition systems also include chemical reagents which appear one color if mixed correctly or another color if incorrectly mixed. The visual recognition system may be internal or external to the apparatus to be diagnosed. An audio recognition system relates to any sound that may be generated from the equipment, i.e., a buzzer.
[0026] The present invention may also use a direct link between the medical apparatus and the portable computer assembly, work station, laptop, computer on a cart, and the like at the remote site so that the host site can analyze the readings/data generated from the apparatus at the remote site. For example, pH, temperature, signal input and output, voltage, flow rates and the like may be monitored directly at the host site to diagnose a piece of equipment. The latter readings and data being exemplary of data important to analyze medical equipment, however, it is within the purview of this invention to enable readings directly from medical apparatus to be input in the remote site assembly for transmission to the host site.
[0027] The assembly and process of the present invention relates to video teleconferencing which may be conducted over the internet or other communication link such as a satellite point to point direct relay, satellite network relay and like connections. FIG. 3 is a schematic diagram which shows the assemblies at the host site and the remote site in communication via a satellite point to point direct relay communication link. FIG. 4 is a schematic diagram which shows the assemblies at the host site and the remote site in communication via a satellite network relay communication link. The assembly of the invention includes a host site, having specified computer equipment, a remote site(s) also having specified computer equipment and a process for video teleconferencing between the respective sites.
[0028] An exemplary list of the equipment used at the host site, at the remote site and the process linking the respective sites are as follows (use of compatible or like equipment may be used in the teachings of this invention):
Host Site System Assembly
[0029] COMPUTER
[0030] The computer system equipment for the host site may include the following:
[0031] A desktop computer with the following features
[0032] Windows 95/98/NT
[0033] 16 MB RAM
[0034] 772 MB HD
[0035] Windows compatible sound system
[0036] 14″ SVGA Color Display
[0037] PCI bus architecture
[0038] ADDITIONAL VIDEO HARDWARE—Only necessary for video duplexing (receiving and sending).
[0039] For full duplexing of video (receiving and sending) the host computer system will also require the following additional video hardware:
[0040] A video input device such as a Toshiba Noteworthy Notebook CCD Camera
[0041] A PCI video digitizing card such as the Micro Video DC30
[0042] INTERNET CONNECTION
[0043] The computer system preferably includes the following Internet related hardware, software, and services:
[0044] A dedicated ISDN router/hub such as the Ascend Pipeline 75.
[0045] A standard ISDN digital telephone line (an example of a communication link. Use of other communication links, as discussed above, are within the purview of this invention).
[0046] Microsoft TCP/IP network protocol configured for Internet connectivity (Explorer, Netscape or like compatible software may also be used).
[0047] An Internet Service Provider relationship (internet connection).
[0048] COMMUNICATION LINK (alternative connections)—Can be utilized with or without internet connection.
[0049] Means for satellite point to point direct relay, satellite network relay connection, electromagnetic wave transmission, graviton radiation wave transmission and radio frequency wave transmission.
Remote Site Assembly
[0050] COMPUTER
[0051] The computer system equipment for the remote site include the following:
[0052] A Notebook computer with the following features:
[0053] Windows 95/98/NT
[0054] 16 MB RAM
[0055] 772 MB HD
[0056] Windows compatible sound system
[0057] 10.4″ Active Matrix Display
[0058] 2×PCMCIA Type II Expansion Slots
[0059] ADDITIONAL VIDEO HARDWARE
[0060] The computer will also use the following video hardware:
[0061] A portable video input device such as a Toshiba Noteworthy Notebook CCD Camera
[0062] A PCMCIA Type II video digitizing card such as the Toshiba Noteworthy Video Capture Card
[0063] INTERNET CONNECTION
[0064] The computer system will also use the following Internet related hardware, software and services:
[0065] 36.6 band modem (minimum)
[0066] standard analog telephone line (minimum)
[0067] Microsoft remote access configured for Internet connectivity
[0068] An Internet Service Provider relationship (internet connection)
[0069] COMMUNICATION LINK (alternative connection)—Can be utilized with or without internet connection.
[0070] Means for satellite point to point direct relay, satellite network relay connection, electromagnetic wave transmission, graviton radiation wave transmission and radio frequency wave transmission.
[0071] The above list of computer equipment at the host and remote sites represent exemplary and minimum requirements for purposes of practicing the present invention. As is known, computer equipment, software, communication links and related devices may change rapidly and it is within the purview of this invention to utilize such computer equipment, software and related devices having added function, power and capacity.
The Process of Creating a Video Conferencing Session
[0072] HOST CONFIGURATION AND PROCESS STEPS
[0073] To set up a video conferencing session the host site creates the following computer environment:
[0074] 1. All local computers and routers are powered on;
[0075] 2. Connection to the internet or other communication link, such as satellite connection is established;
[0076] 3. Identifying the receiving (remote) system's IP address;
[0077] 4. Initiate the video capture subsystem, as identified above (video duplexing only)
[0078] 5. Execute Microsoft Netmeeting 2.0 or above or the like;
[0079] 6. Turn on receive calls with video/audio; and
[0080] 7. Communicate to the remote site the IP address of the receiving computer.
[0081] REMOTE SYSTEM CONFIGURATION AND PROCESS STEPS
[0082] To set up a video conferencing session the remote system creates the following computer environment:
[0083] 8. The notebook or work station computer is powered on;
[0084] 9. Connection to the internet via ISP connection or other communication link, such as satellite connection is established;
[0085] 10. Identifying the host system receiving system's IP address (as provided in step 7 above);
[0086] 11. Ensure that the Notebook video capture subsystem is working correctly;
[0087] 12. Execute Microsoft Netmeeting 2.0 or above or the like;
[0088] 13. Turn on send calls with video/audio; and
[0089] 14. In Netmeeting 2.0 or the like software initiate a communication session with the host system's IP address.
Functions and Purposes of the Assemblies and Processes
[0090] In summary, the assemblies and processes of the invention may be utilized to provide the following procedures which are often encountered in the medical equipment diagnostic field:
[0091] 1. Technical and application troubleshooting;
[0092] 2. Instrument installation assistance;
[0093] 3. Technique monitoring and training;
[0094] 4. Technical training;
[0095] 5. Parts replacement assistance;
[0096] 6. Instrument and parts identification;
[0097] 7. Instrument performance verification;
[0098] 8. Staff/personnel monitoring;
[0099] 9. Client and staff counseling; and
[0100] 10. Enhancement of sales and service capabilities.
[0101] Further, industrial, research and medical institutions are able to use the assemblies and processes of this invention for handling the services set forth above. The assemblies and processes can also be used to analyze not only medical device problems, but the chemicals (consumables, reagents) that are used to generate the test results for patients and quality control. It is within the purview of this invention that similar or like assemblies for the host and remote sites be usable for performing the processes of the invention.
[0102] [0102]FIG. 2 is a schematic diagram showing the steps utilized between the host site and the remote site(s) to practice the present invention. A typical sequence of events is as follows:
[0103] Step 1: Establish A Contractual Relationship
[0104] The Host Technical Service Center and a Remote Site having a medical or other application, or an intermediary of the Remote Site, engage in the formation of a contract to provide technical service with regard to the medical or other application. The Host Site may provide services to the Remote Site by contracting in any of a variety of ways.
[0105] If a Remote Site wants the equipment to stay at their facility, they can lease or rent the equipment and provide their own Remote System Operator. If a Remote Site does not want the equipment to stay at their facility, the Host can provide service by either sending an independent contractor, who leases or rents the equipment, to the remote site; send the equipment to a person in the Remote Site's area that is able to provide service under a single visit contract; or send the equipment with a Host employee to the Remote Site to provide service.
[0106] Step 2: Providing the Proper Equipment
[0107] The Host Technical Service Center (Host Site) has technical personnel, service information, and an audio-visual teleconferencing system (Host System). The Remote Site obtains a portable audio-video teleconferencing system (Remote System) that can communicate with the Host System. The Remote Site may obtain a temporary Remote System, provided by the Host Technical Service Center, that can be stored at the Remote Site indefinitely.
[0108] Step 3: Initial Set-Up
[0109] The Remote Site System Operator (Remote System Operator) sets up the Remote System in close proximity to the medical or other application that is to be the subject of the telecommunications session and establishes a connection between the Host System and the Remote System via a communications link, preferably over the Internet, via satellite point to point direct relay, satellite network relay, radio frequency wave transmission or other communication connection.
[0110] Step 4: Verifying the Contractual Relationship
[0111] Once the Remote System is set up, the Remote System Operator confirms that a contractual relationship is in effect. This can be accomplished via telephone, facsimile, or via the audio-video telecommunications system once a communications connection is established. Host Site Personnel confirm the contract and authorize the service session to commence.
[0112] Step 5: Technical Services Provided
[0113] The Host Technician operating the Host System can provide a variety of services including: training, troubleshooting, and guidance on calibration and maintenance. These services are completed by providing instruction to the Remote Operator based upon the information available to the Host Technician at the Host Site, information conveyed from the Remote Operator and other Remote Site personnel via the linked audio-video telecommunications systems, and the Host Technician can see and hear the operation of the application via the linked audio-video telecommunications systems. Further, the Remote Site Operator can move the Remote System to give the Host Technician a different perspective which may aid the Host Technician in providing proper information to the Remote Site personnel.
[0114] Step 6: Documentation
[0115] As shown in FIG. 1, the equipment at the host site includes software. It is preferred that such software includes means to track and maintain history of the remote site and the equipment and procedures there located. As shown in FIG. 2, prior to sign off, all services that have been provided at the remote site are documented. Thus, a history and steps taken at any remote site is kept in the computer system at the host site. It is within the purview of the invention to maintain a PMI (Preventative Maintenance Inspection) docket in the software at the host site so that proper maintenance and./or verification procedures are indicated. At the direction of the host site, the latter information may be sent to or maintained on the remote site computer assembly.
[0116] Step 7: Ending the Session
[0117] Once services have been provided, the Remote System Operator disconnects the communications connection. The Remote System Operator then either moves the Remote System to a new medical or other application for which the current Remote Site needs assistance, stores the system away at the Remote Site, or reconfigures the device to be taken with the Operator. The device may then be shipped back to the Host Site or may be kept by the Operator until the next job depending on the arrangement between the Operator and the Host Site.
[0118] Although medical application services are discussed herein, the assemblies and processes of the invention may also be utilized to perform services relating to other applications, i.e., relating to the repair, installation, calibration and operation at remote sites of equipment in other industries, for example, industrial machines, tools and equipment, industrial process equipment, telecommunication equipment, heavy construction equipment, agriculture, food processing, food service, electronic and packaging equipment, and heating, vacuum and air conditioning equipment and the like.
[0119] In summary, the computer equipment and software equipment discussed herein are exemplary and compatible and like equipment and software may be used in the teachings of this invention. Further, the host site may be more than one in number, i.e., wherein two operators skilled in respective arts are networked to communicate with one or more remote sites. Furthermore, one or more host sites may simultaneously be linked to a plurality of remote sites i.e., to conduct a training session.
[0120] As many changes are possible to the embodiments of this invention utilizing the teachings thereof, the descriptions above, and the accompanying drawings should be interpreted in the illustrative and not the limited sense. | An assembly and process for video telecommunication between a host site and a remote site for medical applications. The host site and remote site have computer assemblies constructed and arranged to form a computerized video telecommunications system between them. The remote site includes medical apparatus and procedures having visual and/or audio recognition systems whereby training, service, troubleshooting and instrument installation assistance can be conducted from the host site. The video telecommunication system at the host and remote sites include networking software for the communication of audio and visual signals between the sites. The communication between the host site and remote site may be direct communication or communication over the internet. The communication link between the host site and remote site may include an analog telephone line, a digital telephone line, an analog wireless network, a digital wireless network, a fiber optic cable, a satellite transmission network, an electromagnetic wave network, a graviton radiation wave network and a radio frequency wave network. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. patent application Ser. No. 11/548,454, filed Oct. 11, 2006, now U.S. Pat. No. 7,597,782, which issued on Oct. 6, 2009, the disclosure of which is hereby incorporated by reference in its entirety.
BACKGROUND
Generally, the paper manufacturing process employs a machine that systematically de-waters a pulp slurry which consists largely of cellulose wood fibers, along with various chemical additives used as fillers and functional components of the paper or paper products. The pulp is prepared from various species of wood, by basically either of two pulping methods: chemical digestion to separate the cellulose fibers from lignin and other natural organic binders, or by mechanical grinding and refining. The resulting cellulose fibers are used in the manufacture of paper products whereby the pulp is supplied to a paper machine system, slurried in water to various solids levels (consistency), and ultimately diluted to about 0.5-1.0% solids for subsequent de-watering to form a sheet of paper. The low consistency of solids is necessary in order to facilitate fast drainage on the former while achieving proper fiber-to-fiber contact and orientation in the sheet. De-watering begins on the former, which is a synthetic wire or mesh that permits drainage to form a wet-web.
The web is then transferred into the machine press section and is squeezed between roller nips and synthetic press felts (predominantly comprised of nylon) to further remove water, and then through a dryer section comprised of steam-heated roller cans. Finally, the sheet is wound onto a reel. Other process stages can include on-machine surface sizing, coating, and/or calendaring to impart functional paper characteristics.
Generally, the wet-web is approximately 20% solids coming off of the former, 40% solids after leaving the press section, and about 94-97% solids (3-6% moisture) as the paper on the reel. Various chemical compounds are added to the fiber slurry to impart certain functional properties, to different types of paper. Fillers such as clay, talc, titanium dioxide, and calcium carbonate may be added to the slurry to impart opacity, improve brightness, improve sheet printing, substitute for more expensive fiber, improve sheet smoothness, and improve overall paper quality. Also, various organic compounds are added to the fiber slurry to further enhance paper characteristics. These include: sizing agents (either acid rosin, or alkaline AKD or ASA) to improve sheet printing so the ink doesn't bleed through the sheet, starch for internal fiber bonding strength, retention aids to help hold or bind the inorganic fillers and cellulose fines in the sheet, brightening compounds, dyes, etc. Therefore, as the sheet is de-watered on the paper machine, many types of deposits can result on the papermaking equipment. These deposits result from the chemicals used in the process, along with the natural wood compounds that are not thoroughly removed from pulping processes, or from inclusion of recycled fiber in the pulp slurry, and as a result of water re-use.
The primary function of the press-felt fabrics (other than a means of sheet conveyance) is to aid in the de-watering process of the wet-web. The press felts act like blotters or sponges that receive water that is expressed from the web by the pressure of the roller nips. On most modern paper machines, the water is then removed from the press felts by vacuum elements in the press, consisting of the Uhle boxes and suction press rolls. The press felts return in their travel loop back to the nip, to continually receive and transport water away from the web. Consequently, the press felts become contaminated with various types of soils resulting from the web compounds, and from the process shower waters used to flush the felts. Additionally, available chlorine is used in the treatment of paper machine press shower waters, which are used for felt washing and conditioning, in order to prevent microbial growths that result in slime formation that subsequently causes plugging of the shower nozzles. The residual chlorine, however, is detrimental to the nylon press fabrics. Over-treatment, or long-term accumulative effects of available chlorine can cause attack of the polyamide to the point where felt fiber shedding occurs, and press felt integrity is lost. Not only does this cause premature wear, and shorten the useful life of the press felt, but the fractured nylon fibers that become loosened from the felts contaminate the paper.
Additionally, if the paper is surface treated in the manufacturing process, i.e., on-machine coated or sized, these surface treatment systems become contaminated with the nylon-felt fibers, by transference. Sheet defects can become predominant, as manifested in “blade scratches”, when felt fibers are “snagged” by a blade coater.
Prior felt washing methods, used during the papermaking process, have relied upon dedicated chemical showers. There are four basic types of felt showers. Flooding showers are low pressure, high volume showers that flush loose particles and maintain the evenness of the water distribution in the felt. These are most effective at removing contaminants when used in conjunction with the nip of an inside felt carrying roll and require adequate vacuum to remove water volume. Flooding showers are used in tissue applications and on bleed-thru prone fine paper pickup felts.
Lubricating showers are low pressure, low volume shower used to apply a thin lubricating film of water to the felt prior to contact with a suction box to reduce wear and friction and act as a seal for the suction box. These showers apply a fan spray into the nip of the suction box with an overlapping coverage.
Chemical showers are low pressure, lower volume showers used to apply chemicals to the felt. These are most effective at removing contaminants when used in conjunction with the nip of an inside felt carrying roll. For maximum efficiency/dwell time, this shower should be placed as close to the sheet felt split and as far from the suction box as possible.
High Pressure showers are low volume showers used to physically dislodge contaminants from the felt. These are most efficient when placed close to a supporting roll.
High pressure cleaning of felts is best accomplished with an oscillating needle jet at controlled pressures. Proper oscillation of the high-pressure shower to assure uniform felt coverage is essential to an efficient felt conditioning system. Improper shower oscillation can result in a streaky felt appearance. Some sections of the felt do not receive showering and become filled while other sections of the felt receive partial or uniform showering.
All modern paper machine press sections are equipped with high pressure oscillating needle showers, just prior to the Uhle or vacuum box, as standard equipment from the machine manufacturer. These showers are provided as a means of mechanical cleaning, in order to both “chisel” away surface deposits and to loosen soils deep within the press felts void volume or base cloth. As an example, the oscillating needle showers may operate at pressures typically in the range of 150-250 psi, equipped with 0.040″ orifice spray nozzles, which are space 3″-6″ apart. These showers are designed to oscillate so as to allow the needle jets to cover the entire cross-machine direction of the press felt. The oscillation speed should ideally be matched to the rotation frequency of the press felt, so as to cover a cross-machine directional distance equal to the nozzle jet diameter, i.e., 0.040″, within the time of one nip rotation of the fabric (typically 2-4 seconds). Additionally, the shower oscillation stroke distance is often twice the needle-jet shower spacing, in order to obtain double full spray coverage of the felt. This is to compensate for a possible spray void area, should a nozzle become plugged.
Although chemicals have been applied to felts using high pressure showers at low part per million concentrations, these chemicals were limited to “conditioners” or preventative soil agents applied on a continuous basis. The high operating pressure of the needle poses difficulty in achieving sufficient cleaner concentrations to achieve adequate soil removal, so as to restore felt void-volume sufficiently, to improve felt permeability and water transport in a short period of time, such as 10-60 minutes per cleaning application. Applying sufficient cleaning composition to the felt on a continuous bases is cost prohibitive.
Further cleaning press fabrics “on-the-run”, while manufacturing paper, by injecting a detergent cleaner into the intrinsic high-pressure oscillating needle showers of a press felt, so as to remove papermaking soils for maintaining adequate press fabric de-watering, must be accomplished without adding water to the press, without disrupting the papermaking process (sheet breaks), and without causing off-quality product or sheet defects. Thus, high pressure showers have not been used for remedial or restorative chemical cleaning of press felt.
SUMMARY
The present invention encompasses application of the cleaning agent to the high pressure oscillating needle showers on a pulsed basis, with sufficient cleaning duration so as to apply full detergent coverage across the entire press fabric. The addition of cleaning agent is then discontinued for a period of time and then repeated. The cleaning agent(s) may be applied in proportion to press fabric mass, among the various press felt position on a given machine, so as to cost-optimize a press felt cleaning program.
Moreover, although applied wash time is an important parameter to consider for any on-the-run washing method, not only in light of reaction time of the cleaning chemistry upon different soil types at a given concentration, it is preferable that the wash duration will be at least equal to the period of time required to achieve full coverage of the needle jets' oscillation, as described earlier. The minimum duration of a single wash period is a function the felt rotation speed, versus the oscillation speed of the high-pressure needle shower. Preferably, the wash period should last long enough to achieve “double full coverage” by the needle jets. The wash period can be any multiple of the full coverage period.
Moreover, the washing event can be repeated multiple times over the course of a day, everyday, as needed, in order to remove soils and optimize upon the fabrics de-watering capability. Hence, use of a timer, or preferably a PLC can be used for multiple, daily wash events to optimize the press felt cleaning program.
Preferably, more than one chemical cleaning agent is administered, during a cleaning cycle or during alternate cleaning cycles. For example one can alternate between an alkaline and acidic detergent, in order to optimize cleaning efficacy for a variety of soil types.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of a press felt run partially broken away.
FIG. 2 is a diagrammatic depiction of the system used to feed cleaning agents to an oscillating needle shower.
DETAILED DESCRIPTION
FIG. 1 shows an exemplary view of a portion of a run of a papermaking felt. In this embodiment, the felt 10 runs in the direction of arrows 12 over various rollers (not shown). A high pressure oscillating needle shower 14 applies chemical to felt 10 immediately upstream of double UHLE box 16 . The particular location of the high pressure shower is a matter of choice. Further, various low pressure showers are typically used to treat the felt 10 . The selection and location of these is determined by the particular application, and forms no portion of the present invention.
Further, as shown in FIG. 2 , a chemical feed system 40 includes apparatus to introduce one or more cleaning fluids into the high pressure flow of liquid to the oscillating shower 14 . As shown in FIG. 2 , there are two cleaning chemical reservoirs 42 and 44 both with pumps 46 and 48 used to draw cleaning solution from reservoirs 42 and 44 and direct these upstream of a high pressure pump 50 which directs liquid, generally water, from a reservoir 51 or other source to the needle shower 14 . Pumps 46 and 48 are controlled by a PLC 52 which controls the amount of chemical pumped as well as the timing of the introduction of the chemicals, as discussed below,
Although FIG. 2 shows two chemical reservoirs 42 and 44 , it is possible to have only one chemical reservoir with one pump, or, alternately, three or more selected chemicals. However, the selection of two chemicals, as discussed below, is preferred.
According to the present invention, a cleaning chemical is forced through the high pressure needle nozzles 14 as paper is being manufactured. However, the chemicals are introduced on an intermittent basis.
As discussed above, the needle showers produce a very small, approximately 0.04 inch diameter, spray of water at a very high pressure, generally 150 to 250 psi, directly against the felt. Typically, the oscillating needle showers include a series of the needle nozzles spaced 3 inches to 6 inches apart, each with a 0.04 inch spray diameter. Thus, at any one time, the needle shower contacts only a small portion of the felt. Therefore, the nozzles are oscillated back and forth as the felt moves. Over a period of time, which depends upon the speed of the felt and the speed of the oscillation, the entire felt will be uniformly contacted with the spray from the needle showers. This period of time is referred to hereinafter as the full coverage period.
The needle showers themselves are operated continuously during the entire period of time that paper is being manufactured. Therefore, any time that the felt is moving, the needle showers should be applying the high pressure spray of material against the felt, and should be oscillating back and forth to ensure full coverage.
A cleaning solution is added intermittently through the needle showers as paper is being manufactured. The cleaning solution must be injected through the nozzles for a period of time at least equal to the full coverage period, and, preferably, for twice the full coverage period. This ensures that the entire felt is contacted with the cleaning solution. Subsequent to this period of time, the addition of the cleaning solution through the needle shower is discontinued. However, the papermaking process and the application of water without cleaning solution through the needle nozzle continues.
The actual duration of the full coverage period depends upon the felt rotation speed so as to achieve full coverage with the oscillating needle shower (the stroke timed to speed matching of the felt rpm per 0.040 inches movement). For a four felted machine at higher operating speeds, i.e., 3000-3600 fpm, the cleaning solution feed is on for about 15 minutes maximum each hour. This provides for double full coverage.
For a three-felted machine at the same speed, 20 minutes per hour is sufficient. For slower speeds, i.e., 2200-2800 fpm, 24 minutes of treatment each hour is optimal Generally, the minimum off time between cleaning applications will be at least one full coverage period. The inactive time, i.e., the period of time between cleaning times, should be no longer than 50 minutes. If the period of time between cleaning is too long, too much soil will fill the felt. Applying the cleaning chemical operation at least once per hour causes a cumulative effect on the felt providing significant cleaning for the felt.
The cleaning solution used in the present invention can be any cleaning solution typically employed to clean papermaking felt. Depending upon the chemistry of the particular equipment, these cleaning compositions can be alkaline, acid, anionic, or nonionic. Therefore, one will select one or more cleaning compositions, based on the particular papermaking operation. Generally, they will include, in addition to surfactants and the requisite acid or base wetting agents, chelants and sequestrants. Exemplary formulations for both acid and alkaline cleaning compositions are set out below (parts by weight).
Alkaline Felt Wash
water
63.4-73.4
potassium hydroxide
15.0-20.0
complex phosphate
5.0-15.0
surfactant amphoteric
0.1-0.75
chelant
2.0-5.0
sequestrant
0.2-1.0
Acidic Felt Wash
water
66.0-78.0
organic acid (acetic)
10.0-20.0
phosphoric acid sequestrant
5.0-15.0
surfactant amphoteric
1.0-4.0
glycol ether solvent
2.0-8.0
chlorine scavenger
0.05-0.25
The chemical compositions are generally added at about 200 to 600 ppm on a 100% actives basis. The detergent compositions themselves, however, are generally diluted and contain about 15-20% actives.
Since the total amount of soil which is deposited within a press fabric is basically proportional to the felt area, and since all press fabrics on a given machine are the same width (differing by their length), then the amount of press felt cleaner for each press felt can optimally by applied in proportion to the fabric's length, to achieve the same degree of cleanliness. It is best to adjust the concentration of the detergent applied to each felt based upon relative length and soil loading, rather than adjusting detergent feed duration. If the detergent feed duration were varied proportionally in the following example, the coverage of the oscillating needed shower coverage would not result in uniform application of the cleaner. For instance, for a given tri-nip press on a fine paper machine, the Pickup, first bottom press, and third top press felts all have a width of 320″, and the following lengths respectively: 76′, 55.5′ and 46 feet. Thus, in proportion to their area, the press felts would be allocated approximately: 43%, 31% and 26% respectively, of the daily detergent allotment.
In a preferred embodiment, two different cleaning agents are applied alternately with spaced time intervals between the applications. As shown in FIG. 2 , in a preferred embodiment the two different cleaning agents, one alkaline the other acid, or, alternately, one anionic and one nonionic, or one alkaline or acid and the second one neutral, are applied by apparatus 40 shown in FIG. 2 . In this embodiment, the two different chemicals are stored in reservoirs 42 and 44 controlled by pumps 46 and 48 , which, in turn, are controlled by a PLC 52 . Pumps 46 and 48 inject the chemical into the inlet line 60 between the pump 50 and the needle shower 32 . In a preferred embodiment, one of the cleaning solutions is applied for a period of time, preferably equal to twice the full coverage period. The PLC will discontinue the flow of the cleaning solution for a period of time, generally for the remaining portion of the hour. Next, the PLC will inject the second cleaning solution through the needle shower 14 , preferably for twice the full coverage period. The PLC will then discontinue application of cleaning solution for a period of time. This will be repeated continuously while the papermaking machine is producing paper.
The invention will be further appreciated in light of the following example.
Example
Improved Paper Machine Sheet Quality, Runability, and Yield
A test was performed on a fine paper machine equipped with a Twin-ver press, plus straight-through third press and smoothing press, which produced light and medium basis weight free sheet paper grades. Previously, this machine had attempted to enact soils prevention by use of a cleaner continuously, through the high-pressure showers, with insufficient results. As a result, downtime cleaning of the press fabrics (no paper being manufactured on the reel) was required with an alkaline detergent. This not only caused loss of paper production, but also led to culled production during manufacturing, due to sheet defects that occurred in between the intervals of downtime washing events. These defects, i.e., corrugations, wrinkles, and ridges were caused by variation in cross-direction (CD) moisture content of the sheet. This was caused by soiling of the press felts, and due to the fact that no “on-the-run” felt washing capability was available to correct the problem. Additionally, no machine moisture adjustments were available other than dry weight headbox control.
The test consisted of application of alternating two cleaning compounds through the high pressure showers of each press fabric at various frequencies and durations, and measuring the effects upon felt Uhle box vacuums, press filtrate de-watering rates, press felt water permeability profiles, press felt service life, sheet quality, and machine runnability and up-time. The best results were observed when an acid and alkaline cleaner were alternated every other hour, at the rate of 24 minutes on and 36 minutes off, each hour (12 feed cycles each, per day), at a concentration in the range of 0.12-0.15%. This novel cleaning program resulted in huge improvements to the paper machine's production and quality yield, buy lowering CD sheet moisture variation (improvement in reel-shape, and fewer sheet breaks during felt washing). The overall results of the new cleaning program were as follows:
The trial machine monthly total losses for wrinkles were reduced to 19.1 Tons during the 4-month trial period, from 58.2 Tons (pre-trial) and a monthly average of 54.3 tons. Annualized this would result in a reduction of cull loss for wrinkles of 469.2 Tons.
The trial machine monthly total losses for ridges was reduced to 7.8 Tons during the 4 month trial period, from 71.1 Tons (Pre-trial) and a monthly average of 34.8 tons. Annualized this would result in a reduction of cull losses for ridges of 759.6 Tons.
The trial machine monthly total losses for corrugations was reduced to 41.5 Tons during the 4-month trial period, from 65.6 Tons (Pre-trial) and a monthly average of 38.8 tons. Annualized this would result in a reduction in culls for corrugations of 289.2 Tons.
The sum total of estimated reductions in annual culls for ridges, wrinkles and corrugations is 1,518 Tons for this trial machine.
Total cull losses for ridges, wrinkles, and corrugations on the trial machine's winder and super calendar were substantially lower in almost every category, during the trial period.
The present invention, when compared to standard cleaning methods, provided significant improvement in water permeability of the press fabric over its entire service life. There was, further, a significant reduction in the vacuum as measured at the UHLE box.
Further, alternating alkaline and acidic cleaners utilizing the method of the present invention further provided significantly improved results versus using only alkaline or only acidic cleaners. Hence, alternating cleaning chemistry types can increase felt void volume and improve felt dewatering performance over the useful life of the felt.
Further, due to the fact that the present invention uses relatively low concentration of cleaning solution, generally around 0.2 percent, whereas a standard cleaner might be used at a much higher rate, such as 3 percent, has relatively no impact on paper quality. Thus, the cleaning can be conducted while paper is being manufactured without causing sheet defects or sheet breaks. Further, since a relatively small amount of cleaning is applied, there is minimal impact on the cost of the paper. Further, the cost in chemicals is significantly less than the expense occurred in down time required to clean the felt off line.
This has been a description of the present invention along with the preferred method of practicing the invention. However, the invention itself should only be defined by the appended claims. | An apparatus is described for cleaning papermaking felt by applying a low concentration of a cleaning solution through the oscillating needle nozzles. The detergent is applied intermittently while paper is being manufactured. Each cleaning period lasts for at least the length of time required for the nozzles to cover the entire surface of the felt, and preferably twice that period of time. The application of cleaning solution is then discontinued for a period of time. This cycle is repeated continuously as the paper is being manufactured. The apparatus includes a first cleaning chemical reservoir, a second cleaning chemical reservoir, a high pressure pump coupled to the first and second reservoirs, and a control unit having programming for selectively injecting the chemicals. | 3 |
FIELD OF THE INVENTION
This invention is directed to a novel cleaning solvent. More particularly, the invention is directed to a dry-cleaning solvent comprising a linear silicon comprising oligomer, and the solvent unexpectedly results in excellent cleaning properties.
BACKGROUND OF THE INVENTION
In many cleaning applications, it is desirable to remove contaminants (e.g., stains) from substrates, like metal, ceramic, polymeric, composite, glass and textile comprising substrates. Particularly, it is highly desirable to remove contaminants from clothing whereby such contaminants include dirt, salts, food stains, oils, greases and the like.
Typically, dry-cleaning systems use organic solvents, like chlorofluorocarbons, perchloroethylene and branched hydrocarbons to remove contaminants from substrates. In response to environmental concerns, other dry-cleaning systems have been developed that use inorganic solvents such as densified carbon dioxide, to remove contaminants from substrates. The systems that use organic or inorganic solvents to remove contaminants from substrates generally employ a surfactant and a polar co-solvent so that a reverse micelle may be formed to trap the contaminant targeted for removal. Other dry-cleaning systems employ cyclic siloxanes in dry-cleaning solvents.
The use of organic solvents, however, is no longer favored since preferred organic solvents, like halogenated hydrocarbons, often lead to environmental hazards and health risks. Also, densified carbon dioxide is not always a desired solvent since machines that use such a solvent can be dangerous since they operate at very high pressures. Cyclic siloxanes, like organic solvents, are believed to be associated with environmental and health problems since studies indicate they produce liver and lung diseases in laboratory animals.
It is of increasing interest to develop cleaning solvents that do not possess environmental and safety risks. This invention, therefore, is directed to a cleaning solvent comprising a linear silicon comprising oligomer. Such a solvent unexpectedly results in excellent cleaning properties and has no known environmental and safety risks.
BACKGROUND REFERENCES
Efforts have been disclosed for cleaning clothing. In U.S. Pat. No. 4,012,194, the dry-cleaning of garments is disclosed.
Other efforts have been disclosed for cleaning garments. In U.S. Pat. No. 5,683,977, a dry-cleaning system using densified carbon dioxide and a surfactant adjunct is disclosed.
Still other efforts have been disclosed for cleaning clothing. In U.S. Pat. No. 5,942,007, dry-cleaning with cyclic siloxanes is disclosed.
Also, in U.S. Pat. No. 4,685,930, the use of cyclic siloxanes for cleaning is disclosed.
SUMMARY OF THE INVENTION
In a first aspect, this invention is directed to a cleaning solvent comprising a linear silicon comprising oligomer.
In a second aspect, this invention is directed to a dry-cleaning solvent comprising a linear silicon comprising oligomer of the formula:
wherein each R is independently a substituted or unsubstituted linear, branched or cyclic C 1-10 alkyl, C 1-10 alkoxy, substituted or unsubstituted aryl, aryloxy, trihaloalkyl, cyanoalkyl or vinyl group, and R 1 is a hydrogen or a siloxy group having the formula:
Si(R 2 ) 3 (II)
and each R 2 is independently a linear, branched or cyclic C 1-10 substituted or unsubstituted alky, C 1-10 alkoxy, aryloxy, substituted or unsubstituted aryl, trihaloalkyl, cyanoalkyl, vinyl group, amino, amido, ureido or oximo group, and R 3 is an unsubstituted or substituted linear, branched or cyclic C 1-10 alkyl, or hydrogen, hydroxy or OSi(R 2 ) 3 whereby R 2 is as previously defined, and x is an integer from about 0 to about 20.
In a third embodiment, this invention is directed to cleaning substrates with the above-described cleaning solvents.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
There generally is no limitation with respect to the solvent comprising the linear silicon comprising oligomer that may be used in this invention other than that the solvent may be employed to clean a substrate. Often, however, the solvent comprising the linear silicon comprising oligomer is one which may be used to dry clean clothing, and preferably, is one having the formula:
wherein each R is independently a substituted or unsubstituted linear, branched or cyclic C 1-10 alkyl, C 1-10 alkoxy, substituted or unsubstituted aryl, aryloxy, trihaloalkyl, cyanoalkyl or vinyl group, and R 1 is a hydrogen or a siloxy group having the formula:
Si(R 2 ) 3 (II)
and each R 2 is independently a linear, branched or cyclic C 1-10 substituted or unsubstituted alkyl, C 1-10 alkoxy, aryloxy, substituted or unsubstituted aryl, trihaloalkyl, cyanoalkyl, vinyl group, amino, amido, ureido or oximo group, and R 3 is an unsubstituted or substituted linear, branched or cyclic C 1-10 alkyl, or hydroxy, or OSi(R 2 ) 3 whereby R 2 is as previously defined, and x is an integer from about 0 to about 20.
The most preferred solvent used in this invention is one wherein each R is methyl, R 1 is Si(R 2 ) 3 , R 2 is methyl and R 3 is methyl. Preferably, x is an integer from about 0 to about 10, and most preferably, is an integer from about 2 to about 5, including all ranges subsumed therein.
The solvent comprising the linear silicon comprising oligomer that may be used in this invention is often made by equilibration of the appropriate proportions of end capped and monomer units according to the reaction: MM+ x D→MD x M. Such a reaction is generally known as a equilibration reaction, and is catalyzed by an acid or a base. Similar reactions are depicted in Silicone Surfactants , as edited by Randall Hill, Marcel Dekker (Vol. 96) 1999, the disclosure of which is incorporated herein by reference. Other similar descriptions of the synthesis of similar oligomers may be found in U.S. Pat. Nos. 3,931,047 and 5,410,007, the disclosures of which are incorporated herein by reference. Also, the solvents are often made commercially available by Dow Corning (e.g., Dow Corning 200 (R) fluids) and The General Electric Company.
It is noted that while the solvent comprising the linear silicon comprising oligomer may comprise of linear silicon comprising oligomer, it is also within the scope of the invention for the solvent to consist essentially of or consist of the same. Moreover, as used herein, oligomer is defined to mean a compound represented by formula I wherein x is an integer from about 0 to about 20.
When dry-cleaning clothing or garments, for example, with the cleaning solvent comprising the linear silicon comprising oligomer described in this invention, the type of machine that may be used for the dry-cleaning process is the same or substantially the same as the commonly used dry-cleaning machines used for dry-cleaning with perchloroethylene. Such machines typically comprise a solvent tank or feed, a cleaning tank, distillation tanks, a filter and solvent exit. These commonly used machines are described, for example, in U.S. Pat. No. 4,712,392, the disclosure of which is incorporated herein by reference.
Once the garment is placed in the machine and the solvent of this invention is fed into the machine, the normal cleaning cycle is run (typically between ten (10) minutes and one (1) hour) and the garment is cleaned. Thus, in order to demonstrate cleaning, it is not required to add anything to the cleaning machine other than the garment and the linear solvent of this invention.
In a preferred embodiment, however, the cleaning solvent of this invention further comprises from about 0.001% to about 5.0%, and preferably, from about 0.01% to about 1.0%, and most preferably, from about 0.1% to about 0.3% by weight of a silicone oil, based on total weight of cleaning solvent and silicone oil, including all ranges subsumed therein. The silicone oil often preferred in this invention is an alkoxylated polydimethylsiloxane with a molecular weight from about 600 to about 20,000. The silicone oil preferably has ethoxy and/or propoxy pendents, with ethoxylated pendents being especially preferred. It is also noted that such an alkoxylated polydimethylsiloxane may also have alkoxylated end functionalization; however, a silicone oil with less than 50% of all sights on the silicone oil backbone capable of being functionalized ethoxy groups is especially preferred. Illustrative examples of such silicone oils are Silwet 7622, 7602, 7605, 7600, 7230 and 7200, all of which are commercially available from Witco.
In addition to silicone oil, it is especially preferred to add from about 0.01% to about 10.0%, and preferably, from about 0.05 to about 1.0%, and most preferably, from about 0.1 to about 0.5% by weight of a polar additive (e.g., C 1-10 alcohol and preferably water), based on total weight of cleaning solvent, silicone oil and polar additive, including all ranges subsumed therein. Such an addition (silicone oil and water) to the cleaning solvent is often desired so that cleaning may be enhanced, for example, by the formation of reverse micelles.
In another preferred embodiment, it is within the scope of this invention to employ (with or without silicone oil and/or water) 0.001% to about 10%, and preferably, from about 0.05% to about 0.25%, and most preferably, from about 0.1 to about 0.20 by weight of at least one member selected from the group consisting of an unfunctionalized siloxane and a functionalized siloxane (based on total weight of cleaning solvent and unfunctionalized or functionalized siloxane), including all ranges subsumed therein.
The unfunctionalized siloxane is similar to the cleaning solvent represented by formula I, except that X is greater than 20, and the functionalized siloxane is one having a molecular weight ranging from about 300 to about 20,000. The former is commercially available from The General Electric Company and the latter is commercially available from Goldschmidt, Inc. The preferred functionalized siloxane is an amine functionalized siloxane wherein the functionalization is pendent and/or end functionalization, with less than about 50% of all sights on the siloxane backbone capable of being functionalized having amine functionalization. Such functionalized and unfunctionalized siloxanes are typically desired in this invention to act as softeners when clothing is being cleaned.
The samples which follow are provided to illustrate and facilitate an understanding of the present invention. Therefore, the examples are not meant to be limiting and modifications which fall within the scope and spirit of the claims are intended to be within the scope and spirit of the present invention.
EXAMPLE 1
A beaker was charged with 400 grams of olive oil and 25 grams of annatto seeds. The resulting mixture was stirred (about 2 hours) and heated (about 50° C.) until a resulting solution was obtained with a dark amber tint. The solution (tinted olive oil) was used to make the test stain in the Examples which follow below.
EXAMPLE 2
Sets of four (4) polyester cloths, about 5 cm×5cm, were inscribed with a pencil to form circles in the center of each cloth having diameters of about 2.5 cm. 100 microliters of the tinted olive oil from Example 1 were applied with a micropipet to the inside of the circle of each cloth. The resulting sets of stained cloths were aged overnight. The stained cloths were used in the Examples which follow below.
EXAMPLE 3
Four stained cloths prepared in Example 2 were placed in a 250 mL beaker along with 100 mL of linear silicon comprising oligomer available from Dow Corning (Dow Corning 200® Fluid, R, R 1 and R 3 of formula I as methyl, x=2, Mw about 310). The stained cloths were agitated in the oligomer, for about 15 minutes, with an IKA Labrotechnik stirrer set at 225 rpm. The resulting cleaned cloths were removed from the solvent and dried in an oven set at about 39° C.
The cleaning results were measured by placing the cleaned and dried cloths in a Hunter Reflectometer. The R scale, which measures darkness from black to white, was used to measure stain removal. The cleaning results were reported as the percent stain removal according to the following formula: % stain removal = stain removed stain applied = cleaned cloth reading - stained cloth reading unstained cloth reading - stained cloth reading × 100
For this experiment, 42.2% of the olive oil stain was removed.
EXAMPLE 4
The experiment of Example 4 was conducted in a manner similar to the one described in Example 3 except that Dow Corning 200® fluid (x=3 and Mw about 384) was used in lieu of the fluid having x=2 with a Mw of about 310. For this experiment, 32.3% of the olive oil stain was removed.
EXAMPLE 5
The experiment of Example 5 was conducted in a manner similar to the one described in Example 3 except that 50/50 polyester/cotton blend cloths were used in lieu of the 100% polyester cloths. For this experiment, 24.3% of the olive oil stain was removed.
EXAMPLE 6
The experiment of Example 6 was conducted in a manner similar to the one described in Example 5 except that the oligomer of Example 4 was used in lieu of the oligomer of Example 3. For this experiment, 12.9% of the olive oil stain was removed.
EXAMPLE 7
The experiment of Example 7 was conducted in a manner similar to the one described in Example 3 except that 100% cotton cloths were used in lieu of 100% polyester cloths. For this experiment, 17.2% of the olive oil stain was removed.
EXAMPLE 8
The experiment of Example 8 was conducted in a manner similar to the one described in Example 7 except that the oligomer of Example 4 was used in lieu of the oligomer of Example 3. For this experiment, 9.9% of the olive oil stain was removed.
The data in the Examples above indicates that excellent cleaning properties result when the oligomers of this invention are used in dry-cleaning, even in the absence of additional additives. | The invention is directed to a dry-cleaning solvent and method for dry-cleaning. The dry-cleaning solvent and method employ a linear silicon comprising oligomer that unexpectedly results in excellent cleaning properties in the absence of any known environmental or health risks. | 3 |
BACKGROUND
1. Field
This disclosure relates to relates to hydraulic jacks; and, more particularly, to hydraulic jacks that are used to raise and lower loads.
2. General Background
Hydraulic jacks used to raise and lower loads are well known in the art. Such jacks are usually rolled or otherwise placed under a load that it is desired to lift, such as a vehicle, then a lever is activated to raise the saddle of the jack that engages the load placed thereon. When it is desired to lower the load, the lever is used to release the jack and lower the saddle and thus the load placed thereon. However, should the hydraulic mechanism used to raise and lower the jack malfunction, then the jack may drop the load too quickly possibly resulting in injury to the operator.
There is need for an hydraulic jack that has lowering control means for preventing the jack from being lowered out of control while lifting the load placed thereon due to malfunction or the like.
SUMMARY
It is an object of this invention to provide a hydraulic jack having means for controlling the lowering of the jack during lifting in case of a malfunction or the like.
It is a further object of this invention to carry out the foregoing objects wherein the means for controlling lowering of the jack during lifting includes a mechanism built into the spaced side plates of the jack.
These and other objects are preferably accomplished by providing a hydraulically activated jack having a pair of spaced interconnected side plates, a lift arm assembly pivotally mounted between the side plates, and a saddle mounted at top of the lift arm assembly adapted to be placed under the load to be lifted. The jack includes an hydraulically activated power assembly coupled to the lift assembly for raising and lowering the same. Means for limiting the lowering of the jack during lifting of the lift assembly is provided.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned features and objects of the present disclosure will become more apparent with reference to the following description taken in conjunction with the accompanying drawings wherein like reference numerals denote like elements and in which:
FIG. 1 is perspective view of a jack in accordance with the teachings of the invention;
FIG. 2 is a side view, partly in section, illustrating the inner mechanism of the jack of FIG. 1 ; and
FIGS. 3 to 7 are views similar to FIG. 2 showing further steps in the operation of the jack of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
A jack 10 in accordance with the teachings of the invention is shown in FIG. 1 . Jack 10 has a pair of spaced side plates 11 , 12 with integral outwardly extending flanges 13 on each side plate 11 , 12 (only plate 13 on side plate 12 shown in FIG. 1 ). Block members 14 , 15 may be provided on the outside of each side of plate 11 , 12 to add weight and stability to jack 10 .
Front axle 16 extends between plates 11 , 12 terminating on the outside of plates 11 , 12 in roller ends 17 having wheels 18 , 19 rotatably mounted thereon as is well known in the art. Ends 17 are threaded at their terminal ends receiving a suitable nut 20 and washer 21 thereon to retain the wheels 18 , 19 in place.
A pair of L-shaped flanges 22 are provided on side plates 11 , 12 at the rear of jack 10 . Each flange 22 holds a castor housing 23 comprised of a downwardly extending U-shaped yoke 24 having a wheel 24 ′ secured to housing 23 by a nut 25 .
A saddle 26 is rotatably mounted to a U-shaped flange 27 in any suitable manner, as, for example, by a downwardly extending pin 27 ′ (shown in dotted lines) fixed on the bottom of saddle 27 loosely and rotatably mounted in a saddle receiver hole 26 ′ (shown in dotted lines in FIG. 2 ) in flange 27 .
Flange 27 is fixedly mounted to a pin 28 extending between a pair of spaced guide links 29 . Links 29 are rotatably mounted at the rear on bolts 30 extending through each side wall 11 , 12 .
A lift arm assembly 31 having spaced downwardly extending side plates 100 is mounted between links 29 pivotally secured at one end to flange 27 and pivotally mounted by means of pin 42 to plates 11 , 12 .
A guide flange plate 43 is mounted on the inner wall 32 of each side wall 11 , 12 . Guide flange plate 43 has an elongated opening 32 therein aligned with a series of grooves 33 formed on inner wall 32 ′. A stop 34 is provided on the inner wall 32 ′. Flange plate 43 has an elongated slot 35 with a pin 36 extending from wall 32 ′ riding therein. Pin 36 may be spring biased, if desired. A roller 37 is mounted between a pair of spaced links 38 with a pin portion 39 ( FIG. 2 ), extending from roller 37 , riding in grooves 33 as will be discussed. Links 38 are rotatably mounted on pin 40 at their rear ends.
A release plate 101 ( FIG. 2 ) has spaced grooves 45 , 46 receiving pins 47 , 48 , respectively, thereon. Release plate 102 has a rearwardly extending extension portion 83 A cylindrical member 49 ( FIG. 1 ) is mounted between spaced links 50 (only one visible in FIG. 1 ) which links 50 are mounted at the rear to pin 40 .
As is well known in the jack art, a conventional hydraulic cylinder 51 is fixed to cylindrical member 49 and moves the same back and forth when cylinder 51 is activated.
Cylindrical member 49 may be spring biased, if desired, in any suitable manner so as to return the same to the initial starting position.
Hydraulic cylinder 51 is activated by means of a handle 52 removably mounted in a handle housing 53 mounted at the front of jack 10 having a socket 54 receiving handle 52 therein. Handle housing 53 is rotatably mounted in any suitable manner and may abut against resilient spacer rollers 55 , 56 mounted between side plates 11 , 12 .
It is to be understood that jack 10 includes a conventional power unit assembly (not shown) of which hydraulic cylinder 51 is a part thereof. Handle 52 , at its lower end, engages the power unit assembly to move cylinder 49 back and forth when pumped up and down. That is, turning handle 52 clockwise and pumping handle 52 raises the saddle 26 . Turning handle 52 counterclockwise lowers saddle 26 , as will be discussed.
As the saddle 26 is lifted, starting from the FIG. 2 position, roller 39 rolls along plate 43 up over the ridges 60 into a respective groove 33 . Thus, saddle 26 , shown in the rest or down position in FIG. 2 , moves upwardly in the direction of arrow 61 in FIG. 3 as handle 52 is moved up and down as indicated by arrow 62 . Roller 39 is shown as rolling in the direction of arrow 63 over ridge 60 and is shown as about to enter a groove 33 . The final “up” position for saddle 26 is shown with roller 39 disposed in one of the forward grooves 33 ( FIG. 4 ).
It should be understood that the rollers 39 entering sequential grooves 33 as handle 52 is activated prevent the saddle 26 from falling prematurely if there is a failure in the power lift system possibly damaging the operator or equipment being lifted.
In order to release roller 39 from groove 33 , a quick release lever 64 is provided. Lever 64 ( FIG. 1 ) is rotatably mounted on a shaft 65 ′ extending between side plates 11 , 12 . Lever 64 is stopped in its forward movement by engagement with a spring biased stop plate 66 ( FIG. 2 ) rotatably mounted on shaft 67 which extends between side plates 11 , 12 . Plate 66 is spring biased by coil spring 68 engaging the bottom of lever 64 encircling pin 69 ( FIG. 2 ) mounted on side plate 12 . A release latch 70 (see FIG. 3 ) is mounted to side plate 12 biased by coil spring 71 (see also FIG. 5 ). Shaft 65 ′ has a downwardly extending extension portion 72 (see also FIG. 6 ) on each end adjacent the inner walls 32 ′ of each side plate 11 , 12 . Link 81 is pivotally connected at 74 ′ to the lower end of each plate 43 and extends to and is fixed to extension portion 72 at point 74 . As will be discussed, pulling link 81 in the direction of arrow 75 ( FIG. 6 ) pulls plates 43 rearwardly in the direction of arrow 75 . A suitable stop 65 may be provided on the inner wall 32 ′ engaged by an extension 77 on extension portion 72 .
When plate 66 is rotated, it rotates shaft 65 ′, extending between side walls 11 , 12 .
Release lever 70 rotates shaft 67 ( FIG. 2 ) which is spaced from shaft 65 ′ and has an extension portion 78 ( FIG. 2 ) adapted to engage release spring biased lever 79 when activated. Lever 79 abuts at one end against hub 80 ( FIG. 2 ) of extension portion 72 having a shoulder 81 thereon. Lever 79 is notched at notch 82 to hold hub 80 in locked position and thus hold guide flange plates 43 in position. When released, notch 82 disengages from shoulder 81 moving the lower end of lever 79 ( FIG. 5 ) against link 83 which has a guide slot 84 therein with pin 83 movable therein. Links 83 extend from plates 102 and are adapted to lift plates 43 upwardly along with pins 39 when lever 79 is released, thus lifting rollers 39 out of slots 33 . Link 83 ( FIG. 4 ) also has spaced guide slots 86 , 87 with pins 88 , 89 , respectively, adapted to ride thereon. Pin 89 also moves along slots 90 in plates 43 .
Thus, in operation, handle 52 is rotated clockwise, as previously discussed, and handle 52 is pumped to raise the jack. At this stage, release lever 64 is in the forward or FIG. 2 position. This is also the stored position of lever 64 , safely out of the way. As previously discussed, rollers 39 move from the FIG. 2 to the FIG. 3 , then to the FIG. 4 position. Lever 64 is then moved rearwardly in the direction of arrow 91 ( FIG. 4 ) and pressed downwardly again in the direction of arrow 91 . As can be appreciated by comparing FIG. 2 to 4 , as lever 64 is moved in the direction of arrow 91 , the lower end of extension portion 78 abuts against the rear end of link 83 moving plates 43 forwardly and raising the same. That is, plates 43 are raised upwardly as indicated by arrow 93 in FIG. 5 thus also moving rollers 39 out of grooves 33 . As rollers 39 moves rearwardly in the direction of arrow 76 ( FIG. 6 ), saddle 26 moves downwardly and rollers 39 move along guide slot 32 . The final position is shown in FIG. 7 and lever 64 can now be raised in the direction of arrow 94 back to the rear or stored position releasing 82 from engagement with shoulder 84 thus returning guide plates 43 to the position shown. Notch 82 thus engages the shoulder 84 in hub 80 holding the hub 80 , and thus spring biased lever 64 , in the FIG. 4 position prior to release.
In summary, lever 64 is in the forward or stored position of FIG. 2 . Saddle 26 is in the lower position shown and the jack 10 may be placed under a vehicle or the like to lift the same. Handle 52 is now rotated clockwise and pumped up and down to raise saddle 26 and thus the vehicle. As the vehicle is lifted, rollers 39 move along grooves 33 , thus preventing a quick full downward drop of jack 10 should a malfunction of the power unit take place. Rollers 39 thus move forwardly into a forward groove as shown in FIGS. 3 to 5 .
When it is desired to lower jack 10 , the operator merely taps lever 64 with his or her foot moving it from the FIG. 1 position to the FIG. 4 position, then pressing it downwardly to lift plates 43 as heretofore discussed this lifting rollers 39 out of grooves 33 . Handle 52 is now rotated counterclockwise lowering jack 10 to the FIG. 2 position.
Although a particular embodiment of the invention is discussed, variations thereof may occur to an artisan and the scope of the invention should only be limited by the scope of the appended claims. | A hydraulic jack comprising a hydraulically actuated saddle movable from a first lowered position to a second raised position, the jack having a handle which, when pumped up and down, hydraulically raises the saddle, lowering control means associated with the jack for preventing premature lowering of the saddle upon malfunction of the hydraulic actuation during raising of the saddle and a release lever engaging the lowering control means adapted to release the same and permit lowering of the saddle when the handle is pumped up and down. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefits of U.S. provisional patent application Ser. No. 62/020,903, filed on Jul. 3, 2014, the entire contents of which is expressly incorporated herein by reference.
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
Not Applicable
BACKGROUND
The various embodiments and aspects described herein are directed to a method and apparatus for deburring a surface.
In machining a metallic component, the component may have a series of machine marks such as swirls and ridges. To eliminate these machine marks, the marks are typically sanded by hand or with a rotary grinder. However, these methods are slow and sometimes ineffective due to the contour of the machined surface.
Accordingly, there is a need in the art for an improved method and apparatus for deburring a metallic surface.
BRIEF SUMMARY
The various embodiments and aspects described herein address the needs discussed above, discussed below and those that are known in the art.
A handheld orbital sander is disclosed. The handheld orbital sander may be operated with one hand and have a sanding attachment that is capable of conforming to the contour of the metallic surface. In particular, the sanding attachment has a threaded shaft that engages a chuck of the handheld orbital sander and a flat landing that helps to stabilize the sanding attachment during use. The flat landing engages the chuck to provide additional support to mitigate wobbling of the sanding attachment during rotational movement thereof. Additionally, the orbital sander is operable with one hand and the orbital sander is a compact unit. As such, the chuck of the orbital sander must optimize space to prevent interference with rotational movement of the sanding attachment. In order to do so, the chuck has an offset cylindrical recess to impart orbital motion to the rotational movement of the sanding attachment. A bearing with threaded inner race is retained within the offset cylindrical recess with a retaining ring that does not protrude inward toward the inner race. This mitigates any interference between the sanding attachment and the chuck that might prevent rotational movement of the sanding attachment during operation of the handheld orbital sander.
More particularly, a sanding attachment attachable to an orbital sander for deburring machine marks on a metallic surface is disclosed. The attachment may comprise a sanding disc and a pad. The sanding disc may have a circular configuration defining a periphery. The disc may have a rough side and a mounting side. The rough side may be substantially flat and have a grit selected for sanding down the machine marks. The mounting side may have a threaded nub.
The pad may have a flexible support for the sanding disc, a rigid base removably attachable to the sanding disc and a threaded shank removably attachable to a chuck of the orbital sander. The base may have a flat area adjacent to the threaded shank that contacts the chuck of the orbital sander to provide additional support during orbital rotation of the chuck.
An outer peripheral portion of the flexible support may be more bendable compared to the rigid base. The outer peripheral portion of the flexible support may be sufficiently bendable so that the sanding disc is capable of deburring an inside corner having a ¼ inch radius.
A central portion of the support may have a threaded hole for receiving the threaded nub of the sanding disc.
The flat area of the base may contact a face of the chuck of the orbital sander.
In another aspect, a deburring kit for deburring machine marks on a metallic surface is disclosed. The kit may comprise a mini orbital sander and a sanding attachment. The mini orbital sander may be small enough to be held and operated with one hand. The sander may have an orbital attachment. The orbital attachment may have an inner member that rotates with respect to an outer member. The outer member may be retained within a housing. The inner member may have a flat face for engagement with a sanding attachment. The inner member may have a threaded hole.
The sanding attachment comprise a sanding disc and a pad. The sanding disc may have a circular configuration defining a periphery. The disc may have a rough side and a mounting side. The rough side may be substantially flat and have a grit selected for sanding down the machine marks. The mounting side may have a threaded nub that can be engaged to the threaded hole of the inner member.
The pad may have a flexible support for the sanding disc, a rigid base removably attachable to the sanding disc and a threaded shank removably attachable to a chuck of the orbital sander. The base may have a flat area adjacent to the threaded shank that contacts the flat face of the inner member to provide additional support during orbital rotation of the sanding attachment and the housing.
An outer peripheral portion of the flexible support may be more bendable compared to the rigid base. The outer peripheral portion of the flexible support may be sufficiently bendable so that the sanding disc is capable of deburring an inside corner having a ¼ inch radius.
A central portion of the support may have a threaded hole for receiving the threaded nub of the sanding disc.
The inner and outer members may form a bearing held within the chuck with a retaining ring. The retaining ring may have a generally circular shape and be sized and configured to fit within a groove formed in an inner surface of the chuck. The general circular shape of the retaining ring defines curved opposed distal portions so that the retaining ring does not protrude inward and interfere with rotation of the pad. The retaining ring protrudes inward a constant distance around the entire periphery to provide a constant clearance when the sanding attachment is screwed onto the chuck so that the sanding attachment freely rotates during use.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings, in which like numbers refer to like parts throughout, and in which:
FIG. 1 is a perspective view of a handheld orbital sander with a conformable sanding pad for eliminating machining marks on a metallic surface;
FIG. 2 is an exploded perspective view of the handheld orbital sander and the sanding pad;
FIG. 2A is an enlarged perspective view of a chuck of the handheld orbital sander;
FIG. 3 is an exploded perspective view of a chuck of the handheld orbital sander;
FIG. 4 is an exploded perspective view of the chuck of the handheld orbital sander illustrating insertion of a retaining ring within a groove of the chuck;
FIG. 5 is a perspective view of the Chuck of the handheld orbital sander with the retaining ring inserted into the groove of the chuck;
FIG. 6 is a perspective view of the chuck of the handheld orbital sander with a screwdriver used to remove the retaining ring from the groove of the chuck;
FIG. 7 is a perspective view of the chuck of the handheld orbital sander with the retaining ring partially removed from the groove of the chuck;
FIG. 8 is an exploded perspective view of the sanding attachment; and
FIG. 9 is a front perspective view of the sanding attachment.
DETAILED DESCRIPTION
Referring now to the drawings, a compact handheld orbital sander 10 with a sanding pad 12 for deburring a machine mark 14 off a metallic surface 16 is shown. The sanding pad 12 rotates in two different rotational axes which are parallel to each other. Also, the sanding pad 12 has an outer peripheral portion which is conformable to the metallic surface 16 so that the user may press down on the metallic surface 16 to conform the outer peripheral portion 68 of the sanding pad 12 to the contour of the metallic surface 16 for deburring machine mark 14 . To operate the orbital sander 10 , the user grips the body 18 of the sander 10 and depresses the trigger 20 . The orbital sander 10 is a pneumatic operated sander and rotates the sanding pad 12 about a first rotational axis. Also, the first rotational axis is rotated about a second rotational axis which is parallel to the first rotational axis. By providing a compact handheld orbital sander 10 with the sanding pad 12 , the user may efficiently and effectively deburr and eliminate machine marks 14 from a metallic surface 16 .
Referring now to FIG. 2 , the orbital sander 10 has a chuck 22 . This chuck 22 rotates about rotational axis 24 in the direction of arrow 26 . Additionally, the chuck 22 has an inner bearing 28 having an outer race 30 and an inner race 32 . The outer race 30 is secured to the chuck 22 and rotates off of its central axis 34 . The inner race 32 rotates about the central axis 34 . Moreover, the inner race 32 is attached to the outer race 30 by way of ball bearings. As such, the inner race 32 does not necessarily rotate at the same rotational speed as the outer race 30 . When the sanding pad 12 is attached to the chuck 22 , the sanding pad 12 rotates about both axes 24 , 34 . This provides superior deburring capabilities to remove machine marks 14 on a metallic surface 16 .
The orbital sander 10 may have a custom chuck 22 for allowing the sanding pad 12 to be securely mounted to the chuck 22 so that the sanding pad 12 does not wobble during deburring operations and rotates freely. More particularly, the chuck 22 may have a cylindrical configuration and may be mounted to an arbor of the orbital sander 10 . The arbor of the orbital sander 10 rotates the chuck 22 about its central axis 34 which is also the rotational axis 24 . The chuck 22 has a cylindrical recess 36 which receives the inner bearing 28 . The inner bearing 28 is frictionally mounted to the chuck 22 in that an outer diameter of the inner bearing 28 may be press fit into the cylindrical recess 36 . To retain the inner bearing 28 in the cylindrical recess 36 , an retaining ring 38 may be disposed within a groove 40 formed in the inner surface of the cylindrical recess 36 .
The retaining ring 38 may be a resilient elongate curved member. The retaining ring 38 when not disposed within the grooves 40 (i.e., in its natural state) is larger than an inner diameter 42 of the cylindrical recess 36 . When the retaining ring 38 is installed, the inner bearing 28 is completely disposed within the cylindrical recess 36 and the groove 40 is exposed. The retaining ring 38 is pushed into the groove 40 and springs outward so that the retaining ring 38 is retained within the grooves 40 to prevent the inner bearing 28 from being dislodged out of the chuck 22 during use.
The retaining ring 38 is slender and does not protrude inward to provide as much space for the sanding pad 12 . Moreover, the retaining ring may have a constant diameter so that the retaining ring 38 protrudes inward at most a thickness of the retaining ring 38 . The sanding pad 12 is connected solely to the inner race 32 so that during rotation of the chuck 22 , the sanding pad 12 does not contact other parts to prevent rotation of the sanding pad 12 during operation.
To assemble the chuck 22 , the inner bearing 28 is pushed into the cylindrical recess 36 . The inner bearing 28 is completely disposed within the cylindrical recess 36 and the groove formed on the inner surface of the cylindrical recess 36 is exposed and can receive the retaining ring 38 . Referring now to FIG. 3 , once the inner bearing 28 is disposed within the cylindrical recess 36 , the retaining ring 38 is positioned in the cylindrical recess 36 as shown in FIG. 4 . Initially, one side of the retaining ring 38 is disposed within the grooves 40 . The other side of the retaining ring 38 overhangs the chuck 22 . The user pushes the portion of the retaining ring 38 that overhangs the chuck 22 with his or her thumb 44 toward the center of the chuck 22 . The retaining ring 38 material is selected so that pressure from the thumb may be capable of sufficiently deflecting the retaining ring 38 to lodge the retaining ring 38 into the groove 40 of the cylindrical recess 36 . When the retaining ring 38 is disposed within the groove 40 , as shown in FIG. 5 , the retaining ring 38 protrudes inward and blocks the inner bearing 28 from vibrating out of the cylindrical recess 36 during operation. The opposed distal end portions do not protrude inward as in prior art retaining rings. In this manner, the sanding pad 12 does not contact the retaining ring 38 or any other part to prevent or hamper rotation of the sanding pad 12 during operation.
To remove the retaining ring 38 from the groove 40 , the chuck 22 has a notch 46 that extends at least partially into the groove 40 . When the retaining ring 38 is disposed within the grooves 40 , the notch 46 provides space so that a screwdriver 48 may be inserted into the notch 46 to push in the retaining ring 38 in the direction of arrow 50 to dislodge the retaining ring 38 out of the groove 40 , as shown in FIG. 7 . The retaining ring 38 is removed from the chuck 22 to fix or maintain the orbital sander 10 or the internal parts of the chuck 22 .
The sanding pad 12 includes a sanding disk 52 and sanding bit 54 . The sanding bit 54 and the sanding disk 52 are removably attachable to each other through a threaded connection. In particular, the bottom side of the sanding bit 54 has a threaded hole 56 . Also, the sanding disk 52 has a threaded nub 58 . The threaded nub 58 is screwed into the threaded hole 56 to attach the sanding disk 52 to the sanding bit 54 or unscrewed from the threaded hole 56 to remove the sanding disk 52 from the threaded hole 56 .
The sanding bit 54 may be fabricated from a resilient polymeric material (e.g., rubber). The outer peripheral portion 60 of the sanding bit 54 may encapsulate an inner central portion 62 fabricated from a metallic or nonrigid material. The threaded hole 56 may be formed in the inner central portion 62 . The inner central portion 62 may extend from the bottom surface of the sanding bit 54 to the upper side of the sanding bit 54 . The inner central portion 62 provides stability and rigidity to the sanding pad 12 as the user applies pressure onto the metallic surface 16 to conform the outer peripheral portion 60 of the sanding pad 12 to the contour of the metallic surface 16 . The inner central portion 62 may have a flat landing 64 . The flat landing 64 of the inner central portion 62 may butt up against the flat face of the inner race 32 when the sanding pad 12 is attached to the sander 10 . The flat landing 64 provides additional stability during rotation of the sanding pad 12 by the sander 10 . This prevents the sanding pad 12 from wobbling during operation.
The sanding pad 12 may have a generally rigid central portion 66 . An outer peripheral portion 68 may be flexible and conform to the underside of the outer peripheral portion 60 of the sanding bit 54 as the user pushes down on the sanding pad 12 to conform the sanding pad 12 to the metallic surface 16 .
The above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise variations that are within the scope and spirit of the invention disclosed herein, including various ways of attaching the sanding disc 52 to the sanding bit 54 . Further, the various features of the embodiments disclosed herein can be used alone, or in varying combinations with each other and are not intended to be limited to the specific combination described herein. Thus, the scope of the claims is not to be limited by the illustrated embodiments. | A method and apparatus for deburring a metallic surface is disclosed. The method and apparatus utilizes a handheld orbital sander that is compact so that machine marks disposed in tight places can be reached. Additionally, a conformable sanding pad is utilized to allow the sanding pad to conform to the unique contours of the metallic surface to eliminate the machining marks. | 1 |
FIELD OF THE INVENTION
The present invention relates to an apparatus and method for accelerating food product in order to cause the product to be stretched aligning the fibers of the product.
BACKGROUND OF THE INVENTION
Current forming technology relies on high pressure, speed and complicated material flow pathways which produce a product lacking in quality. High pressure works the meat cells, the higher the pressure the more massaging or squeezing of the meat cells takes place. High speed combined with a complicated flow path massages and works the meat product, releasing myosin/actin from the cells causing the muscle fiber to bind together and contract (protein bind). The contraction takes place during high heat application as in cooking. The action of the meat fiber is to contract in length, this contraction combined with protein bind not only shortens the muscle fiber which if not controlled causes odd cook shapes but a rubber like texture with a tough bite.
In muscle, actin is the major component of thin filaments, which together with the motor protein myosin (which forms thick filaments), are arranged into actomyosin myofibrils. These fibrils comprise the mechanism of muscle contraction. Using the hydrolysis of ATP for energy, myosin heads undergo a cycle during which they attach to thin filaments, exerting a tension, and then depending on the load, perform a power stroke that causes the thin filaments to slide past, shortening the muscle.
Muscle fibril structure is measured from micrometers to several millimeters in length. These fibril structures are bundled together to form muscles. Myofibril proteins are the largest group and probably more is known about these proteins than any other. In muscle cells actin is the scaffold on which myosin proteins generate force to support muscle contraction. Myosin is the major protein that is extracted from the muscle cells by mechanical means.
An important purpose of tumbling and massaging is to solubiliize and extract myofibril proteins to produce a protein exudate on the surface of the meat. The exudates bind the formed pieces together upon heating. Binding strength also increases with increased massaging or blending time. This is due to increased exudate formation on the surface of the meat. Crude myosin extraction is increased with increased blending time.
Grinding/chopping utilizes the concept of rupturing the cell to release protein. This mechanical chopping or shearing takes place at the shear/fill plate hole. This process extracts actin and myosin from muscle cells.
Mixing, utilizes friction and kinetic energy to release protein extraction. Fill hole shape and spacing can cause dead spots and turbulence in the meat flow. This change of direction is a form of mixing and massaging. This is another process, which extracts actin and myosin from muscle cells.
Massaging, utilizes friction and kinetic energy to increase protein extraction. This action takes place almost anywhere meat comes in contact with processing equipment and is moved or has a change of direction via pressure. This is also a procedure which involves extracting actin and myosin from muscle cells.
SUMMARY OF THE INVENTION
It is an object of the present invention for the fiber orientation technology to reduce the release and mixing of myosin with actin. It is an object of the present invention for the fiber orientation technology to control orientation of the fiber. It is an object of the present invention for the fiber orientation technology to provide less myosin activity resulting in a better bite/bind and control over the final cook shape.
The present invention relates to an apparatus and method for accelerating food product in order to cause the product to be stretched aligning the fibers of the product. It is an object of the present invention for a hole or orifice to change size from a larger to a smaller cross-sectional area with vertical or concave sides having a sharp edge. The principle has design similarities to a venturi. It is referred to as a choke plate, nozzle, venturi, orifice, or a restriction to flow which results in product acceleration with a corresponding pressure drop through the orifice.
By reducing the cross-sectional area of a tube through which a substance passes, the velocity is increased. This is the principle of Conservation of Mass. When the velocity increases the pressure of the material is reduced. This is the principle of the Conservation of Energy.
For every liquid, there is a ratio between the cross-sectional area (C) and the cross-sectional area (c) through which velocity can only be increased by reducing temperature or increasing pressure. Although ground meat is not a homogeneous liquid, the same concepts still apply. It is impossible to attain choked flow unless there is a transition between the orifices and the small orifice has a finite length.
A venturi allows a smooth transition from a larger orifice to a smaller one. This transition minimizes flow transitions and thereby reduces restrictions in the system. The transmission minimizes energy loss and supports fiber alignment.
The transition in a venturi is extremely difficult to create in a production tooling environment. As a result, using the geometric properties of a sphere or similar shape allows the ability to obtain many of the venturi effect properties using standard production practices.
All points on a sphere are the same distance from a fixed point. Contours and plane sections of spheres are circles. Spheres have the same width and girth. Spheres have maximum volume with minimum surface area. All of the above properties allow meat to flow with minimum interruptions. There are not static or dead zones. No matter what angle the cylinder intersects the sphere, the cross section is always a perfect circle.
It is an object of the present invention to increase meat velocity forcing linear fiber alignment.
It is an object of the present invention to have spherical geometry or a similar shape in fill or stripper plate to create venturi effects.
It is an object of the present invention for the process to make a patty cool uniformly and soften the texture/bite of the product.
The present invention relates to a food patty molding machine having a mold plate and at least one mold cavity therein. A mold plate drive is connected to the mold plate for driving the mold plate along a given path, and a repetitive cycle, between a fill position and a discharge position. A food pump is provided for pumping a moldable food product through a fill passage connecting the food pump to the mold cavity when the mold plate is in the fill position. A fill plate, interposed in the fill passage adjacent to the mold plate has a multiplicity of fill orifices distributed in a predetermined pattern throughout an area aligned with the mold cavity when the mold plate is in fill position. It is an object of the present invention for the fill orifices to define paths through the fill plate, wherein some of the paths each have a path portion obliquely angled or perpendicular to the fill side of the mold plate. It is an object of the present invention for the paths to comprise spherical intersections or a curved structure. It is an object of the present invention for the side of the fill plate which is in contact with the stripper plate to comprise a spherical hemisphere or curved structure which has a cross sectional area between approximately 1.5 to 3.0 times greater than a cylindrical portion which intersect the top of the mold plate perpendicularly or at an angle of less than or equal to +/−75 degrees, or +/−45 degrees in a preferred embodiment as measured from vertical in the longitudinal direction of the mold plate. By a reduction in the cross-sectional area a “choked-flow” condition is created. By using spherical sections or a curved structure, intersections between cylinder and spheres or curved structures create transitions which can be manufactured whose geometry approaches a venturi style system. It is preferred to have a sharper edge from the edge to the hole. It is an object of the present invention to make the edge sharper with a grinder. It is an object of the present invention for the fill plate to be chrome coated on the side adjacent to the stripper plate with a material significantly harder than the fill plate material. This is because the stripper plate wears out. The piece is 39 Rockwell C. It becomes approximately 60-65 Rockwell C. It is an object of the present invention for the material to be applied in a thickness to facilitate a surface which cuts the food product upon movement of a stripper plate. The material goes from 1/1000 th of an inch to 5/1000 th of an inch with the chrome. A cutting hemisphere into bottom of plate, with a cylinder.
It is an object of the present invention for the stripper plate to be interposed in the fill passage immediately adjacent to the fill plate. It is an object of the present invention for the stripper plate to be movable in a direction transverse to the mold plate, between the fill and discharge locations. It is an object of the present invention for the stripper plate to have a multiplicity of fill openings aligned one-for-one with the fill orifices in the fill plate when the stripper plate is in fill position. It is an object of the present invention for the stripper plate drive to be synchronized with the mold plate drive, such that the movement of the stripper plate facilitates the cutting of the meat product, which was pushed through the fill plate by the food pump. It is an object of the present invention for the stripper plate drive to move the stripper plate to its discharge position, in each mold cycle, before the mold plate moves appreciably toward the discharge location. It is an object of the present invention for the stripper plate drive to maintain the stripper plate in the discharge position until the mold plate cavity is displaced beyond the fill orifices.
It is an object of the present invention for the fill paths to be in a direction to the front or rear of the machine. It is an object of the present invention for all fill paths to consist of a hemispherical shape which is intersected by a cylindrical shape at an angle less or equal to +/−75 degrees of vertical, and preferably +/−45 degrees of vertical.
It is an object of the present invention to use spherical geometry, with cylindrical intersections, and the ratio of the area of the sphere divided by the area of the cylinder greater than or equal to approximately 1.5 to 3.0 to create conditions to meat flow which maintain improved cell structure.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is an unassembled view of a fill plate and stripper plate of the present invention.
FIG. 2 is an assembled view of a fill plate and stripper plate of the present invention.
FIG. 3 shows a side view of an embodiment of the invention.
FIG. 4 shows a top view of an embodiment of the invention.
DETAILED DESCRIPTION
FIG. 1 shows an unassembled view of a fill plate 10 , stripper plate 12 and a top plate 14 .
FIG. 2 shows an assembled view of the fill plate 10 , stripper plate 12 and top plate 14 , further comprising a stripper plate spacer and hold down 16 , a cylindrical section 18 and a curved section 20 .
FIG. 3 shows a side view of the patty molding machine having an auger driver motor 30 an auger 32 , knockouts 34 and a shear plate drive cylinder 36 .
FIG. 4 shows a top view of an embodiment of the present invention, having a stripper plate drive 40 , a fill and stripper plate assembly 42 , a mold plate 44 and a draw bar 46 .
The present invention relates to fiber orientation technology. The fiber orientation technology drops pressure across the fill plate, aligns the fibers of meat so that the contraction of the muscle fiber that does take place is in a direction of choice controlling both bite and shrinkage. The fiber orientation technology provides a lower resistance to product flow using a wider opening.
The fiber orientation technology provides a better shear surface for a cleaner cut. The fiber orientation technology aligns the fibers in the fill hole so the shearing action disrupts as few muscle cells as possible. The fiber orientation technology decreases the total area of metal fill plate blocking the meat flow resulting in less direction change to the product which works the meat. The fiber orientation technology pulls the meat fiber through the fill hole instead of pushing using the principles of the venturi/choke plate.
All of these characteristics of fiber orientation technology reduce the release and mixing of myosin with actin, the net effect is a controlled orientation of the fiber, less myosin activity resulting in a better bite/bind and control over the final cook shape.
Spherical geometry in fill or stripper plate creates venturi effects.
The process of the present invention makes a patty cool uniformly and soften the texture/bite of the product.
A food patty molding machine has a mold plate and at least one mold cavity therein. A mold plate drive is connected to the mold plate for driving the mold plate along a given path, and a repetitive cycle, between a fill position and a discharge position. A food pump pumps a moldable food product through a fill passage connecting the food pump to the mold cavity when the mold plate is in the fill position. A fill plate, interposed in the fill passage immediately adjacent to the mold plate has a multiplicity of fill orifices distributed in a predetermined pattern throughout an area aligned with the mold cavity when the mold plate is in fill position. The fill orifices define paths through the fill plate, wherein some of the paths each have a path portion obliquely angled or perpendicular to the fill side of the mold plate. The paths consist of spherical intersections or a curved structure. The side of the fill plate which is in contact with the stripper consists of a spherical hemisphere or curved structure which has a cross sectional area approximately 1.5 to 3.0 times greater than a cylindrical portion which intersect the top of the mold plate perpendicularly or at an angle of less than or equal to +/−75 degrees, or +/−45 degrees in a preferred embodiment as measured from vertical in the longitudinal direction of the mold plate. By a reduction in the cross-sectional area a “choked-flow” condition is created. By using spherical sections or a curved structure, intersections between cylinder and spheres or curved structures create transitions which can be manufactured whose geometry approaches a venturi style system. It is preferred to have a sharper edge from the edge to the hole. To get a perfect edge it is preferred to sharpen with a grinder.
In a preferred embodiment, the fill plate is chrome coated on the side adjacent to the stripper plate with a material significantly harder than the fill plate material. This is because the stripper plate wears out. The piece is 39 Rockwell C. It becomes approximately 60-65 Rockwell C. The material is applied in a thickness to facilitate a surface which cuts the food product upon movement of a stripper plate. The material goes from 1/1000 th of an inch to 5/1000 th of an inch with the chrome. A cutting hemisphere into bottom of plate, with a cylinder.
A stripper plate is interposed in the fill passage immediately adjacent to the fill plate. The stripper plate is movable in a direction transverse to the mold plate, between the fill and discharge locations. The stripper plate has a multiplicity of fill openings aligned one-for-one with the fill orifices in the fill plate when the stripper plate is in fill position. A stripper plate drive is synchronized with the mold plate drive, such that the movement of the stripper plate facilitates the cutting of the meat product, which was pushed through the fill plate by the food pump. The stripper plate drive moves the stripper plate to its discharge position, in each mold cycle, before the mold plate moves appreciably toward the discharge location. The stripper plate drive maintains the stripper plate in the discharge position until the mold plate cavity is displaced beyond the fill orifices.
The fill paths can be in a direction to the front or rear of the machine. All fill paths consist of a hemispherical shape which is intersected by a cylindrical shape at an angle less or equal to +/−75 degrees of vertical, and preferably +/−45 degrees of vertical.
The use of spherical geometry, with cylindrical intersections, and the ratio of the area of the sphere divided by the area of the cylinder greater than or equal to approximately 1.5 to 3.0 creates conditions to meat flow which maintain improved cell structure. | An apparatus and method for accelerating food product in order to cause the product to be stretched aligning the fibers of the product. | 0 |
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to a hand tool and more particularly to a hand tool for turning the screw on a hose clamp.
2. Background Information
Hose clamp screws have a recess and/or hex head for a tool drive end to engage. The recess conventionally is a slot for a blade type driver but sometimes a star for a Phillips type driver. The majority of hose clamps have a hex head and a slot for a blade driver. Regardless of the type of drive the tool must in most instances be pushed against the screw during use and when a clamp is loose on a hose it rotates thus making the task most difficult. To stop the rotation one must apply an equal and opposite force on the clamp or screw.
Tools have been proposed that engage both the nut on a bolt and the bolt head. Reference in this regard may be had to the following United States Patents: U.S. Pat. No. 1,294,857 issued Feb. 18, 1919 to C. Yuncker; and U.S. Pat. No. 1,282,523 issued Oct. 22, 1918 to C. Bauer. The tools in these references have a shaft with a socket drive head end for drivingly engaging the head of a bolt to rotate the same and means resiliently urging it toward a an extension to the tool that has a wrench or socket to hold a nut on the bolt while the head end is rotated. With these tools one must use two hands to force the bite of the tool open against the spring pressure to get it in a work position on the bolt. This is inconvenient and awkward and doesn't leave a hand free to hold other parts and pieces as is often necessary when working with movable things such as hoses and hose clamps.
U.S. Pat. No. 2,910,899 is designed for use with a ring clamp.
SUMMARY OF INVENTION
The hose clamp tool of the present invention includes a base, an elongate post secured to and projecting upwardly from the base, and a support secured to and projecting upwardly from the base and offset laterally from the post. The support terminates in a free upper end. A flip up lid comprising a plate like member and hinge means pivotally attaching the plate like member, adjacent one edge thereof, to the upper end of the support. The lid has a slot extending inwardly from an edge thereof, opposite the hinge, to receive therein a portion of the post.
An object of the present invention is to provide a hose clamp tool wherein the clamp screw is engaged between and in axial alignment with the tool head end of a driver and an anvil on the tool and which can be readily manipulated using only one hand.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawings in which like numerals refer to like parts throughout the several views and wherein:
FIG. 1 is a side elevation view of a hose clamp tool provided in accordance with the present invention;
FIG. 2 is an oblique view of the hose clamp tool shown in FIG. 1;
FIG. 3 is an enlarged view of an outer tip end portion of the tool shown in FIG. 1;
FIG. 4 is similar to FIG. 3 but illustrating an alternative construction; FIG. 5 is an exploded view of the drive end for the tool illustrated in FIG. 1;
FIG. 6 is an alternate embodiment of an outer tip end portion of the tool illustrated in FIG. 1 showing the tip having a rounded shoulder wherein the hole is spaced an equal distance from the bottom and side edges of the shoulder;
FIG. 7 is an end view of the alternate outer tip end portion of FIG. 6 showing the tip having a rounded shoulder and a wedge shape;
FIG. 8 is an alternate embodiment of an outer tip end portion of the tool illustrated in FIG. 1 showing the recess in the body member and a plug of a pin press fit into the aperture in the tool body member;
FIG. 9 is an alternate embodiment of an outer tip end portion of the tool illustrated in FIG. 1 showing the recess in the body member and a plug of a pin press fit into the aperture in the tool body member held in place with a screw disposed into the body member normal thereto in cooperative engagement therewith;
FIG. 10 is an alternate embodiment of an outer tip end portion of the tool illustrated in FIG. 1 showing the recess in the finger of the body member, wherein the aperture in the tool body member is formed integrally therewith of hard material in an elongated slot shape eliminating the need for a pin or plug and the jaw shoulder is formed at an acute angle with respect to the finger;
FIG. 11 is an alternate embodiment of an outer tip end portion of the tool illustrated in FIG. 1 showing the recess in the body member comprising a groove formed therein in alignment with the tool shaft for cooperatively engaging a screw mounted within a clamp;
FIG. 12 is an alternate embodiment of the tool shown in FIG. 1, showing a rubber grommet having base portion sized having the same diameter of the handle and a neck portion sized in accordance with the shaft, joined by a concave tapered middle portion with is a user friendly shape;
FIG. 13 is an alternate embodiment of the tool shown in FIG. 1 showing an adapter having an aperture therein as an attachment which is placed over the outer tip end of the tool and held into position by a friction fit, a tongue and groove arrangement, or snap fit;
FIG. 14 is an alternate embodiment of the tool shown in FIG. 1, wherein the lug is shown including grooves formed therein for gripping;
FIG. 15 is an alternate embodiment of the tool illustrated in FIG. 1 showing the recess in the body member comprising an oval shaped aperture formed therethrough in alignment with the tool shaft for sliding over a distal end of a screw of a clamp being removed and cooperatively engaging a portion of the clamp;
FIG. 16 is an alternate embodiment of FIG. 1, showing the shaft utilizing a flexible longitudinal shaft member within the jaw for allowing flexing of same;
FIG. 17 is an alternate embodiment of the hose clamp tool of FIG. 1, wherein the handle has been removed to show a shaft distal end having a square shank for cooperative engagement to a ratchet, wrench, or screwdriver;
FIG. 18 is an alternate embodiment of the hose clamp tool of FIG. 1, wherein the handle has been removed to show a shaft distal end having a hexagon shaped shank for cooperative engagement to a ratchet, wrench, or screwdriver; and
FIG. 19 is an alternate embodiment of the hose clamp tool of FIG. 1., wherein the handle has been removed to show a shaft distal end having a threaded shank for cooperative engagement to a ratchet, wrench, or screwdriver or other tool.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Illustrated in the drawings, FIGS. 1-19, is a tool 10 comprising a slender elongate body member 20 or frame having a recessed portion at one end forming an open shallow “C” shaped jaw 21 . The longitudinal distal end portion of the jaw 21 of the preferred embodiment further defines a finger 11 curved at about a 90 degree angle with respect to the main body member 20 defining an interior holding surface as the a first abutment 22 on the distal end of the jaw further defining an exterior shoulder portion 12 connected by an outer tip distal end 13 . A second abutment 23 is located at the opposite proximate end of the jaw 21 forming an inner shoulder portion. There is a through hole 25 extending from the proximate end of the jaw 21 through the finger 11 axially aligned with the first and second abutments, 21 and 23 respectively.
Spaced apart from the first abutment 22 and remote from the hole 25 , is an opposing aperture 28 formed in or near the distal end of the finger 11 which is also axially aligned with the hole 25 . The aperture 28 may extend all the way through the finger 11 or extend only enough to form a dimple, notch, elongated notch, or circular depression defining a recess 26 . During use of the tool 10 , the recess 26 receives the free outer distal end of the hose clamp screw. The recess 26 may be in the finger 11 of the body member itself as shown in FIGS. 3 or be formed in a plug or cap of a pin 27 as shown in FIGS. 4 and 8 wherein it is threaded or press fit into the aperture 28 of the finger 11 of the tool body. As shown in FIG. 13, a cover cap forming an anvil 60 may be held into position over the distal end of the finger and be permanently or removably retained by a snap fit, frictional fit, retaining screw of the like, and include a recess 26 therein in alignment with the shaft 30 .
The shaft 30 extends through the hole 25 and has a free outer tool head end 31 adjacent said first abutment 22 . Means for compressing such as a compression spring 32 is disposed coaxially on the shaft 30 . The compression spring 32 has one end abutting against the second abutment 23 of the jaw 21 and the other end abutting against a spring abutment means 33 disposed on the opposing end of the shaft 30 to resiliently urge the tool head end 31 toward the first abutment 22 . A preferred embodiment utilizes a washer 18 disposed between the spring 32 and the second abutment of the body 20 . Means for spacing including a washer of a particular thickness or a plurality of washers 18 may be used to vary the distance the spring 32 is compressed and various size springs may be used to obtain the desired compression strength. The spring abutment means 33 can for example be a C-clip or E-clip snap fit into a groove around, a pin extending traverse to, press pinched areas, or notches in the shaft 30 . A washer 15 such as shown in FIG. 13 may be used as a means for abutting the spring 32 in combination with a means for stopping comprising an C-clip, E-clip, or transverse pin, or press pinched areas on the shaft 30 . It should be noted that a sleeve 14 as shown in FIG. 14 may be inserted within the body 20 coaxially around the shaft 30 to provide a strength and structural support to the body 20 if the tool body 20 is fabricated from aluminum or a plastic material. A small oil port 16 may optionally be formed or drilled into the body to lubricate the shaft 30 rotating therein.
The shaft 30 may end at the second abutment in a male or female means of attachment such as a socket so that a flexible longitudinal shaft member 19 may be permanently or removably attached thereto such as described in U.S. Pat. No. 4,876,929 by Kozak hereby incorporated by reference. The preferred embodiment would include the means for compressing or spring 32 , means for holding the compression means in a compressed state coaxially around the flexible shaft 9 such as the washers 18 and 33 and means for stopping such as the c-clip 33 defined heretofore together with a selected tool head end 31 for engaging a clamp screw or bolt head.
The opposite end of the shaft 30 extends beyond the tool body 20 and the extending portion has a hand grip handle 35 is mounted thereon for use in rotating the shaft 30 with respect to the body 20 . The handle 35 can be fixed to the shaft 30 or alternatively the drive end of the shaft may be a female square socket (not shown) for receiving the male square shaft of a ratchet, a power driven stub shaft on a hand drill or simply a handle 35 with a square at one end to mate with the socket. The handle 35 of the preferred embodiment is plastic; however, it is contemplated that all or a portion of the handle 35 may be rubber coated, include a knurled surface, and/or be fabricated from metal, wood, or combinations thereof. The handle 35 may comprise a hollow body cylinder 16 having a distal end with a threaded surface for cooperatively engaging an end cap 17 having threads or utilize a hollow cylindrical body wherein the end cap is frictionally held thereto for storage of bits such as illustrated in FIG. 13 .
As shown in FIGS. 16-18, the handle 35 may be detachable and the distal end of the shaft 30 extending into the handle 35 may be formed as a square, hex, or threaded socket or male end for cooperatively engaging a ratchet, wrench such as a strong arm tool, electric screwdriver, or drill.
The tool head end 31 is shaped to match the slot, star or hex head as the case may be of the hose clamp screw. Illustrated in FIG. 1 is a blade drive 36 within an optional socket 37 (or recess) in the tool head drive end 31 . The socket 37 receives a portion of the screw head end therein and this together with the recess in the abutment 22 at the end of the screw maintains the drive and screw in axial alignment. In some instances a hose clamp screw head has a slot and peripheral rib shaped like a bolt head that keeps a driver centered on the screw in which case a recess 37 is not required on the driver. For most clamps a socket matching the hex head is all that is required.
The body 20 has a projection defining a lug 50 that is readily engaged by one's thumb while the fingers of that hand are wrapped around the handle. All or a portion of the lug 50 may be covered with a plastic or rubber coating and/or include grooves or a knurled surface for gripping. The lug 50 projects from the body toward the handle 35 overlapping a portion thereof. It is thus possible to pull on the handle 35 with one's fingers on one hand while pressing the thumb on the same hand against the lug 50 to open the bite of the tool 10 against the spring pressure.
To use the tool 10 the shaft 30 is moved by hand pulling the handle 35 while holding the body or frame 20 stationery which compresses the spring 32 and retracts the shaft 30 for engaging or disengaging the head of the clamp screw with the tool head end 31 and to seat the distal end of the clamp screw within the recess 26 . When the shaft 30 is released the hose clamp screw is clampingly engaged between the tool head end 31 and the first abutment 22 and drivingly engaged by the head end 31 . The first abutment, being recessed as at 26 , keeps the tool in position at that end and at the other end the screw head is in the tool head drive end socket 37 . This arrangement maintains axial alignment of the drive shaft 30 and the hose clamp screw. Rotating the handle (by hand or power) turns the screw to tighten or loosen the clamp as desired and while doing so the web portion of the jaw engages the hose thus preventing the tool from rotating. Release of the tool is again a one hand operation. Moreover, rotating the shaft 30 in a selected direction spreads the hose clamp freeing the ribbed portions of the band which may have become embedded in the rubber material comprising the hose.
Details of the preferred drive head end 31 is illustrated in FIG. 5 in which a socket 41 is removably mountable on a square 40 on the end of the shaft 30 . A drive element 42 is removably insertable (if the need should arise) into the socket 41 and can be chosen at the time of use to match the hose clamp screw head at hand. If a blade drive is used the socket should be deep enough to receive a portion of the head of the hose clamp screw.
The handle 35 has a front edge 44 against which abuts a rubber grommet 37 on the shaft. This grommet 37 has a shoulder 38 . During one hand manipulation of the tool the index finger engages this shoulder while the thumb of the same hand bears against the end of the lug 50 . With this grip the shaft 30 is easily forced against the force of the compression spring 32 to open the bite between abutment 22 and the drive socket. Another preferred embodiment of the tool utilizes a plastic or rubber grommet 37 as shown in FIG. 12, wherein the shoulder 38 defines a base portion 46 sized having the same diameter of the handle 35 and a neck portion 48 sized in accordance with the shaft 30 joined by a concave tapered middle portion 49 which is a user friendly shape;
The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom, for modifications will become obvious to those skilled in the art based upon more recent disclosures and may be made without departing from the spirit of the invention and scope of the appended claims. | A tool, for use in turning the screw on a hose clamp, in which a shaft is slidably and rotatably mounted on an elongate slender body member and resiliently biased toward an abutment on the body member to grasp there between the screw on the hose clamp. The shaft has a tool head end to drivingly engage the screw head and at the other end a handle or socket for use in turning the shaft. The abutment on the body has a recess to receive therein the free outer end of the hose clamp screw. This recess and the socket on the drive head end maintain the screw and drive in axial alignment during use. A lug on the body member projects toward and terminates proximate a leading end portion of the shaft turning handle. The lug and its proximity to the handle make it easy to manipulate the tool using one hand. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to student lockers, and more specifically, a locker having remote control locking, opening, and noise-making mechanisms operable by a key chain transmitter.
2. Description of the Related Art
Electronic locking systems for lockers have been the subject of earlier patents. Handicapped persons, especially students in wheelchairs need to be able to locate, unlock, and open their school lockers by remote control. The related art will be discussed in the order of perceived relevance to the present invention. The related art of interest describes various locks, but none disclose the present invention as claimed.
U.S. Pat. No. 5,894,277, issued in April 1999 to Keskin et al., describes a programmable digital electronic lock for a locker. The lock may be opened using a keypad that is permanently mounted to the locker door. Keskin discloses only a solenoid locking mechanism but not the higher efficiency pendulum lock. Moreover, Keskin does not disclose a locker assembly having separate mechanisms that cooperate to both unlock and then open a locker; nor does Keskin a keypad that can signal and cause the triple function of beeping, unlocking, and opening, in distinct intervals. Thus Keskin does not disclose the present invention as claimed.
U.S. Pat. No. 5,933,086, issued in August 1999 to Tischendorf, et al., describes a keyless locking mechanism, with a portable remote to lock and to unlock a house door. The Tischendorf device is not suited to a gym locker and it lacks both the structure and functionality of the present invention.
U.S. Pat. No. 5,678,436, issued in October 1997 to C. E. Alexander, describes a remote control door lock system to remotely lock and unlock the deadbolt on a door. The Alexander device lacks the structure, combination of components, and functionality of the present invention.
United Kingdom Application No. GB 2,159,567, published in December 1985, describes a storage container that unlocks with the use of a remote control. However, the '567 does not disclose a storage receptacle that both unlocks and opens with the remote control, just one that unlocks with the remote control. Nor does it have the additional features such as a release lever, pendulum lock to increase efficiency, or the noise-making mechanism.
Other patents which have some relevance to the present invention include: U.S. Pat. No. 4,778,206, issued October, 1988 to Motsumoto, et al.; U.S. Pat. No. 5,021,776, issued September, 1991 to Anderson, et al.; U.S. Pat. No. 5,261,260, issued November, 1993 to Lin, et al.; U.S. Pat. No. 5,392,025, issued February, 1995 to Figh, et al.; U.S. Pat. No. 5,406,274, issued April, 1995 to Lambropoulos, et al.; U.S. Pat. No. 5,680,134, issued October 1997 to Tsui, P. Y., U.S. Pat. No. 5,896,094 issued April, 1999 to Narisada, et al.; and United Kingdom Patent Application No. GB 2,078,845 published February, 1982.
None of the above inventions and patents, taken either singularly or in combination, is seen to describe the instant invention as claimed. Thus, there is a need for a remotely controlled school locker that is operable by a transmitter on a key chain, and that has one or more, or a combination of the features of the present invention in order to solve the problems of efficiency, security, and versatility.
SUMMARY OF THE INVENTION
The present invention is a remote control mechanism for a storage locker, such as those used in fitness centers, school gymnasiums, employee changing areas, etc. The mechanism, designed especially for handicapped students or employees, enables a locker to be located by an audible signal, unlocked and opened by remote control via a handheld transmitter. The locker assembly includes a transmitter having a first button that activates a door locking mechanism, a second button that activates a door opening mechanism, and a third button that activates a sound-making device, much like the beeper in a wristwatch, in order to help a visually impaired student more easily find his or her locker.
The mechanism includes a receiver that receives signals from the transmitter and which responds to commands that actuate the door locking mechanism, the door opening mechanism, and the noise-making mechanism. Two embodiments of the remote control locking mechanism are presented, the first being a solenoid actuated remote control locking mechanism, and the other being a remote controlled motorized pendulum lock that uses less energy than the solenoid mechanism. The door locking mechanism is particularly useful for students who are visually impaired or who have problems with manual dexterity and are unable to operate the conventional combination lock, enabling them to unlock the locker by remote control and thereafter opening the locker by lifting the handle on the locker door. The door opening mechanism is particularly useful for students who are confined to a wheelchair, and enables them to both unlock and open the locker door by remote control before moving the wheelchair up to the locker.
As stated, the second primary feature of the locker is a door opening device, which may be used in connection with either embodiment of the door locking mechanism. The door opening mechanism unlocks and opens the locker door. The door opening mechanism utilizes a method of lifting the locker door latch pins using a remote controlled, solenoid actuated system of release levers. A cable connecting the solenoid to the release levers causes the levers to rotate about a fulcrum, which urges the locker latch pins off of their corresponding latches.
Similar circuits, each having slightly different values, are used for both the locking mechanisms, and the door opening device. A different circuit is used for the beeping function of the locking mechanism.
Accordingly, it is a principal object of the invention to provide a device that provides students with disabilities, and other students, convenient access to their school lockers.
It is another object of the invention to provide a useful device to employers who offer employee lockers, by providing the option to furnish a locker that can serve the needs of a broader spectrum of employees, most notably those who are disabled or handicapped.
It is a further object of the invention to provide an efficient and versatile locker assembly that can be operated using a remote controlled, handheld, push button device.
It is an object of the invention to provide improved elements and arrangements thereof for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes. These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of a generic embodiment of an automated locker according to the present invention.
FIG. 2 is a front perspective view of the first embodiment of the automated door locking mechanism.
FIG. 3 is a perspective view of the automated door opening mechanism according to the present invention.
FIG. 4 is a front perspective view of a second embodiment of the automated door locking mechanism, showing the locked position.
FIG. 5 is a front perspective view of the second embodiment of the automated door locking mechanism in an unlocked position.
FIG. 6 is a front elevational view of the second embodiment with the locker handle raised.
FIG. 7 is a schematic diagram of the circuit that controls the locking mechanisms of FIG. 2, and of FIGS. 4 through 6, as well as the opening mechanism of FIG. 3 .
FIG. 8 is a schematic diagram of the circuit that controls the noise making device in the present invention.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is directed to a remotely control mechanism for a locker 10 , especially for use by handicapped students or employees. Referring now to the drawings, FIG. 1 is a front perspective view of a school locker equipped with a generic embodiment of the present invention. FIG. 2 and FIGS. 4 through 6 show two different embodiments of a door locking mechanism, showing a locker door 16 to which is mounted enclosure 76 containing remote controlled locking mechanisms 80 and 90 , respectively. FIG. 3 illustrates a remotely controlled door opening mechanism 20 , as distinguished from the aforementioned locking mechanisms. Opening mechanism 20 is connected to door frame 18 of locker 10 . FIG. 7 is a schematic diagram of the preferred circuit used for both the locking mechanisms (FIGS. 2 & 4 ), and for the opening mechanism (FIG. 3) of the present invention. FIG. 8 illustrates the preferred circuit used for a noise-making mechanism of locker 10 .
Referring to FIG. 1, locker 10 includes a transmitter 40 having a plurality of buttons. The transmitter 40 and receiver may operate by radio frequency wave, infrared, or ultrasonic means. According to the preferred embodiment, a first button 50 activates locking mechanisms 80 and 90 . A second button 54 activates door opening mechanism 20 . A third button 58 activates a sound-making mechanism 70 , much like the beeper in a wristwatch. When enabled, this device causes the lock to “beep,” and it is intended to help a visually impaired student to easily find his locker. For the purposes of FIG. 2, and FIGS. 4-6, noise-making transducer 70 is illustrated diagrammatically incorporated or contained in lock enclosure 76 , and has a noise-making circuit, as shown in FIG. 8, disposed within control module 60 . Each automated locker 10 may have its own control module 60 and power supply. In the alternative, multiple lockers may share a power supply, or they may share a power supply and a control module. The power supply could be a battery within the control module itself, or it could be a separate stand alone unit next to the control module.
Still referring to FIG. 1, locker 10 preferably includes a receiver, or control module 60 , that receives signals from transmitter 40 , and provides commands that actuate either of locking mechanisms 80 or 90 , or door opening mechanism 20 . In general, control module 60 includes a power supply and a receiver. More specifically, the following is included in the circuitry of control module 60 : (a) a receiver 61 to detect the signal of the correct transmitter 40 ; (b) timing circuitry, which can be adjusted to keep the door unlocked the necessary time depending upon preference; (c) diagnostic light emitting diodes (LEDs) (not shown) for trouble shooting and/or to indicate the status of the system; (d) an override switch to unlock the locker if the system stops functioning properly; and (e) control module 60 also has a mode of operation switch, including an “ON” switch 63 for permitting automatic door opening by remote control, and an “OFF” switch 65 for requiring manual door opening, that is, where the door automatically unlocks but does not automatically open.
Referring to FIG. 2, enclosure attachment means 100 holds the enclosure lid onto lock enclosure 76 . Plunger 92 , which protrudes from enclosure 76 , is a component of locking mechanism 90 that is used to prevent the opening of locker 10 by limiting the movement of latch pin release plate 102 . When the correct signal is received from transmitter 40 , control module 60 applies a voltage to first solenoid 104 , energizing the solenoid coil and withdrawing the plunger 92 into the magnetic field of the coil, causing it to retract from release plate 102 . Plate 102 can then be lifted, allowing latch pins 26 to raise and to release locker door 16 . After a set amount of time, control module 60 removes voltage from solenoid 104 . When power is cut, plunger spring 94 causes plunger 92 to protrude, so as to again clamp and thereby lock release plate 102 so that it may not be raised.
Solenoid 104 is preferably a standard solenoid as is well known in the industry. However, in order to make the locking mechanism battery operated, and to conserve energy, a latching solenoid or actuator may be used instead of solenoid 104 . In that case, when the correct signal is received from transmitter 40 , control module 60 sends a short voltage spike to the latching solenoid or actuator. This causes the device to go into a retracted state. The device remains in this state until another voltage surge is sent to it. The second surge returns the device to its initial, locked state.
As shown in FIG. 2, wire channel 74 , which is attached to second locking mechanism 90 , protects at least four, but up to seven wires that connect control module 60 to the locking mechanism 80 or 90 within enclosure 76 . Channel 74 creates a pathway through which the wires travel from enclosure 76 in order to reach control module 60 .
Still referring to FIG. 2, key switch 96 is used to power the locking mechanism on and off, and to program a new transmitter code into the system if the previous transmitter 40 , or transmitter code, is lost. A new code is programmed by turning the control module 60 switch to the off position, holding down the transmitter button, and then turning the switch 96 back on.
FIG. 4 is a front perspective view of locking mechanism 80 , which is an alternate embodiment of the locking mechanism shown in FIG. 2 . FIGS. 4 through 6 show pendulum lock 84 , of mechanism 80 , in first, second, and third positions, respectively. Pendulum lock 84 is a wedge-shaped piece of steel mounted on the shaft of motor 86 . FIG. 4 shows locking mechanism 80 in a locked state, with the outside edge of pendulum lock 84 facing down and seated upon, and in mating alignment with, middle seat 64 of lock body 62 . Lock arm 82 , which must be raised in order to open locker door 16 , is a flat piece of steel that is connected to, and preferably made in one piece with, lock body 62 . Body 62 , together with arm 82 , is fixed by standoff screw 89 , which screws into standoff 88 to hold lock body 62 in place, body 62 pivoting about screw 89 within the limits set by recess 75 defined in enclosure 76 . So long as pendulum lock 84 rests upon middle seat 64 , lock arm 82 is held in a locked position. In order for locker 10 to be opened, it is necessary for lock arm 82 to be raised with locker handle 14 . Accordingly, when the correct signal is received from transmitter 40 , control module 60 sends a quick voltage surge to lock motor 86 . This causes pendulum lock 84 to rotate clockwise around its axis about 180° to an unlocked position, as shown in FIG. 5 . In its unlocked state, and even when no voltage is applied to motor 86 , pendulum lock 84 remains upright because one of its side edges is balanced against upper seat 66 of lock body 62 . With lock 84 in an unlocked state, lock arm 82 is free to move upward with locker handle 14 . When locker handle 14 is then raised, pendulum lock 84 rotates counterclockwise, the shift in the center of gravity bringing pendulum lock 84 to a third resting position, as shown in FIG. 6, wherein a side edge of pendulum lock 84 rests upon lower seat 68 of lock body 62 . When locker handle 14 is released, pendulum lock 84 moves to a position where it no longer rests upon lock body 62 , and thus, lock 84 rotates back to the locked position shown in FIG. 4 .
FIG. 3 is a side elevational view of the remotely operated automatic door opening mechanism 20 , which is incorporated in both embodiments of the remote control mechanism, but used as an alternative to either of locking mechanisms 80 and 90 . More precisely, door opening mechanism 20 opens door 16 , independent of door unlocking mechanisms 80 or 90 . The theory of mechanism 20 stems from the fact that latch pins 26 can be lifted in two different ways to open door 16 . The first way, as suggested by FIG. 1, is to manually lift latch pin release plate 102 which is connected to each of the latch pins 26 . The second way is to lift each individual latch pin 26 . Pins 26 are held down by springs. When closing door 16 , pins 26 can be lifted by the camming force upon pins 26 due to the beveled edge of each door latch 24 . This is what allows locker doors to be “slammed” shut without having to lift release plate 102 . Door opening mechanism 20 utilizes a method of lifting pins 26 that is closest to the “second way,” described above. Mechanism 20 includes at least one latch pin release lever 22 for each of the latch pins 26 . A given release lever 22 urges and slides each of pins 26 off of a latch 24 . Latch 24 , standard in the industry, is preferably a rigid, fixed hook, within door frame 18 , that latches, in a camming relationship, onto pin 26 . Latch pin 26 , also standard in the industry, is a spring-loaded pin which, in conjunction with latch 24 , holds locker door 16 shut. Mechanism 20 includes a second solenoid 28 which acts, through release lever cable 30 , upon an end of each lever 22 . Thus, when control module 60 detects the correct signal, a voltage is sent to second solenoid 28 . Second solenoid 28 then pulls down on lever cable 30 causing a release lever 22 in each lever housing 32 to rotate about pivot pin 34 , which acts as a fulcrum, and to thereby lift the corresponding latch pins 26 off of latches 24 . This releases door 16 , permitting door 16 to open. Door 16 may be biased by one or more springs (not shown) in the hinges so that the door 16 automatically swings open when pins 26 are lifted out of hooks 24 . Cable 30 is preferably a steel cable running from each release lever 22 to solenoid 28 . Stated more simply, cable 30 causes lever 22 to rotate about fulcrum 34 to disengage each of the pins 26 from their corresponding latch 24 . Release lever housing 32 encases that portion of lever 22 that is connected to cable 30 and to fulcrum 34 . The side walls of lever slot 36 of housing 32 serve to guide and to support lever 22 as it rotates about fulcrum 34 . Fulcrum 34 is a pin, preferably metal or hard plastic, that is connected to a wall of housing 32 .
FIG. 7 is a schematic diagram of the circuit which controls the locking mechanisms of FIG. 2, and FIGS. 4 through 6, as well as the opening mechanism of FIG. 3 . The circuit shown in FIG. 7 is a timing circuit built around a timer chip T 1 , preferably a Motorola LM555 integrated circuit. The circuit has a power source V 1 which provides direct current at an appropriate voltage, preferably twelve volts. The power source V 1 may be provided by a battery or by a regulated power supply, as is known in the art. Transistor M 1 is an N-channel metal oxide semiconductor field effect transistor (MOSFET) which is used to provide sufficient power, and particularly sufficient current, to energize the coil of solenoid 104 in the first embodiment of the door locking mechanism, shown in FIG. 2, the motor 86 of the second embodiment of the door locking mechanism, shown in FIGS. 4 through 6, or the solenoid 28 of the door opening mechanism, shown in FIG. 1 and common to both embodiments. The switch S 1 /S 2 designates a trigger signal generated by pressing either button 50 or button 54 of the transmitter 40 to unlock the door or to open the door, respectively, and triggers the timer chip T 1 to an “on” state. The timer chip T 1 is wired for monostable (one-shot) operation in this circuit configuration, with the duration of the “on” state determined by the values of resistor R 1 and capacitor C 1 . The output voltage is taken across the terminals O 1 .
When the circuit of FIG. 7 is used with the door locking mechanism of FIG. 2, R 1 has a value of 432 kΩ and C 1 has a value of 100 μF. This sets the duration of the “on” state at about ten seconds. Consequently, when button 50 of the transmitter 40 is pressed, the timer T 1 is triggered to the “on” state and provides an output voltage at terminals O 1 sufficient to cause the solenoid 104 to retract plunger 92 for ten seconds, permitting the locker handle to be raised during this period in order to open the door.
When the circuit of FIG. 7 is used with the door locking mechanism of FIGS. 4 through 6, the value of R 1 is 15.65 kΩ and the value of C 1 is 100 μF. This sets the duration of the “on” state at about one second. The shorter duration of the “on” state is possible in this embodiment because once the motor 86 moves the pendulum 84 to the position shown in FIG. 5, the locker 10 remains unlocked until the handle 14 is used to raise and lower the lock arm 82 . In use, when button 50 is pushed, timer T 1 is triggered to the “on” state for one second, providing an output voltage at terminals O 1 sufficient to drive motor 86 to move pendulum 84 to the unlocked position.
When the circuit of FIG. 7 is used with the door opening mechanism of FIG. 3, R 1 has a value of 15.65 kΩ and the value of C 1 is 100 μF. This sets the duration of the “on” state at about one second. In use, when button 54 is pushed, timer T 1 is triggered to the “on” state for one second, providing an output voltage at terminals O 1 sufficient to energize the coil of solenoid 28 , pulling cable 30 and lifting the latch pins 26 from hooks 24 to open the door.
FIG. 8 is a schematic diagram of the circuit that controls the noise-making device of locker 10 . This circuit has some features similar to the circuit shown in FIG. 7 . V 1 is a power source similar to the power source shown in FIG. 7, and the same power source may be used for both circuits. The output of the circuit is taken across terminals O 1 , and is used to power the transducer 70 . Transistor M 1 is an N-channel MOSFET used to provide sufficient power to drive the transducer 70 . Switch S 3 receives a signal when button 58 is pressed which is used to trigger timer T 1 . Timer T 1 is again a Motorola LM555 integrated circuit wired for monostable operation. Resistor R 1 has a value of 865 kΩ and capacitor C 1 has a value of 100 μF, setting the “on” state duration to a period of about thirty seconds. The circuit of FIG. 8 applies the output voltage of timer T 1 to trigger a second timer T 2 , which is also a Motorola LM555 integrated circuit. Timer T 2 , however, is wired as an astable multivibrator in which the duty cycle and duration of the “on” state of timer T 2 are set by the values of resistors R 2 and R 3 , and capacitor C 2 . Preferred values of the resistors are 14 kΩ for R 2 and 43 kΩ for R 3 , while capacitor C 2 is preferably 100 μF. These values turn the output of timer T 2 to the “on” state for one second and off for three seconds, the pattern repeating for the thirty second duration set by timer T 1 . In operation, when button 58 is pressed, the circuit of FIG. 8 drives the transducer 70 to beep at the rate of one second on and three seconds off for thirty seconds in order to enable the student to locate his or her locker 10 .
All of the values provided for above for the components shown in FIGS. 7 and 8 are merely preferred values that are subject to preferences based upon the individual needs of the user. The signals sent by transmitter 40 to control module 60 may include, but are not limited to, RF, infrared, or sonar to open locker door 16 . In some cases, it is desirable not to have the locker door actually open because the door can be opened by mistake, since control module 60 can receive a transmitted signal from a distance of up to 200 feet. Thus, if a user desires, he or she can enable locking mechanisms 80 , 90 , and disable opening mechanism 20 . Under that option, door 16 would unlock when first button 50 is pushed, but handle 14 would have to be lifted to release, or to open door 16 . Thus, the unlock and the open mechanisms will not be used simultaneously. That is, when one is enabled, the other will be disabled.
The remote control mechanism according to the present invention may be installed as an after-market modification of conventional lockers, or may be supplied as original equipment with newly manufactured lockers.
Similar reference characters denote corresponding features. It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims. | A school locker having remote controlled locking, opening, and beeping functions. The locker includes a key pad transmitter having a first button that activates a locking mechanism, a second button that activates a door opening mechanism, and a third button that activates a sound-making device, much like the beeper in a wristwatch, in order to help a visually impaired student more easily find his or her locker. Two embodiments of the locking mechanism are presented, the first being a solenoid actuated remote control locking mechanism, and the other being a remote controlled motorized pendulum lock. Again, the second feature of the locker is a door opening device, which may be used in connection with either locking mechanism, and which opens the locker door after it is unlocked. The door opening mechanism utilizes a solenoid actuated system of release levers which urge the locker door's latch pins off of their corresponding latches. One electrical circuit is used for the locking mechanisms and the door opening device, and a different circuit is used for the beeping function of the locker. | 4 |
FIELD OF THE INVENTION
The invention relates to aqueous organ preservation solutions and methods useful in surgical operations on the heart and in transplantation of the heart and other mammalian organs.
BACKGROUND OF THE INVENTION
Transplantation of vital organs such as the heart, liver, kidney, pancreas, and lung has become increasingly successful and sophisticated in recent years. Because mammalian organs progressively lose their ability to function during storage, even at ice temperatures, transplant operations need to be performed expeditiously after organ procurement so as to minimize the period of time that the organ is without supportive blood flow. This is particularly true for the heart in which the permissible storage time with present methods of preservation is limited to a maximum of about 4 to 6 hours.
In clinical practice, the two situations in which cardiac preservation is required are heart transplantation and cardioplegia for open heart surgery. In heart transplantation, the donor heart is exposed through a midline sternotomy. After opening the pericardium, the superior and inferior vena cavae and the ascending aorta are isolated. The venous inflow is then occluded, the aorta is cross clamped, and approximately 1 liter of cold cardioplegic solution is flushed into the aortic root under pressure through a needle. As a result, the heart is immediately arrested, and cooling is supplemented by surrounding it with iced saline. The cold arrested heart is then surgically excised, immersed in cold cardioplegic solution, surround by ice and rushed to the recipient center.
The recipient's chest is opened through a midline sternotomy, and after placing the patient on cardiopulmonary bypass, the diseased heart is excised. The preserved donor heart is then removed from the preservation apparatus, trimmed appropriately and sewn to the stumps of the great vessels and the two atria in the chest. After completion of the vascular anastomoses, blood is allowed to return to the heart. It then will either resume beating spontaneously or will require chemical and electical treatment to restore normal rhythm. When the heart is ready to take over the circulation, the cardiopulmonary bypass is discontinued and the recipient's chest closed.
Most non transplant surgical procedures on the heart, such as coronary artery bypass grafting, require that the heart's action be arrested for a period ranging from 1 to 4 hours. During this time, the heart is kept cool by external cooling as well as by periodic reflushing a cardioplegic solution through the coronary arteries. The composition of the latter solution is designed to rapidly arrest the heart and to keep it in good condition during the period of standstill so that it will resume normal function when the procedure is finished.
In the cardioplegic procedure, the heart is exposed in the chest, and as a minimum the aortic root is isolated. A vascular clamp is applied across the aorta and approximately 1 liter of cold cardioplegic solution is flushed into the aortic root through a needle. Venting is provided through the left ventricle, pulmonary artery or the right atrium and the effluent which may contain high levels of potassium is sucked out of the chest. This, together with external cooling, produces rapid cessation of contractions. During the period of arrest, the patient's circulation is maintained artificially using cardiopulmonary bypass.
After completion of the surgical procedure, blood flow is restored to the coronary circulation and beating either returns spontaneously or after chemical and electric treatment. The ease with which stable function is restored depends to a large extent on the effectiveness of preservation by the cardioplegic solution. Once the heart is beating satisfactorily, cardiopulmonary bypass is discontinued and the chest closed.
It is generally understood that "living" organs, including the heart, continue the process of metabolism after removal from the donor so that cell constituents are continuously metabolized to waste products. The accumulation of these metabolic waste products, depletion of cell nutrients and consequent derangement of cell composition lead to progressive loss of function and ultimately to cell death if the storage technique is inadequate. That is, the organ will lose its ability to function adequately after transplantation into the recipient. Several procedures have been successfully explored to enable organs to be preserved ex vivo for useful time periods. In one method the organ to be transplanted is rapidly cooled by flushing cold solutions through the organ's vascular system and maintaining the organ at temperatures near 0° C. for the purpose of greatly slowing the metabolic rate. In the case of the mammalian heart, the flush solution composition is designed to cause the heart to rapidly stop beating as well as to preserve it.
Another method for organ storage utilizes continuous perfusion at temperatures in the range of 7°-10° C. with an oxygenated solution designed to support oxidative metabolism and to remove waste products. A suitable perfusate is delivered through the circulatory system of the isolated organ--usually from the arterial side--and as the perfusate is conveyed through the vascular system waste products are carried away from the organ. Kidneys and livers can commonly be preserved in this manner for several days. However, only limited success has been achieved in preserving the heart, and therefore this method is not used in clinical heart transplantation. The heart must function well enough to sustain a good circulation in the recipient immediately after the transplant operation, whereas some impairment of function can be tolerated in transplanted livers and kidneys. Since hearts can only be preserved for 4-6 hours using cardioplegic solutions, heart transplantation tends to be ruled out in certain situations in which the proposed donor and recipient are far distant from one another.
The viability of a preserved organ depends on a number of factors, among which may be listed (1) cell swelling which occurs at low temperatures as water is transferred across cell membranes in a stored organ, (2) the degree of intracellular acidosis which occurs during non perfused ice storage as a consequence of continued cell metabolism, (3) derangement of internal cell composition which results from impaired metabolism, particularly with respect to cations such as calcium, potassium, magnesium and sodium, and (4) injury caused by oxygen-derived free radicals during oxygenated perfusion or after restoration of the circulation.
Perfusate solutions containing hydroxyethyl starch ("HES") have been reported by Belzer and Southard in Transplantation, 45:673 676, April, 1988, for use in preserving the kidney, liver and pancreas. See also PCT Publication No. WO 87/01940 (published Apr. 9, 1987). The compositions differ depending on whether they are to be used for continuous perfusion or a single flush ice storage of the organ. In both cases, however, a central feature of the solution is the content of the colloid HES.
SUMMARY OF THE INVENTION
We have found that mammalian organs, and particularly hearts, can be preserved for comparatively long periods of time without significant loss in viability through the use of aqueous preservation solutions containing polyethylene glycol having a molecular weight above about 15,000 daltons. The solution ingredients, including an impermeant composition, are pharmacologically acceptable, and the solution desirably is buffered to a pH in the range of from about 7.1 to about 7.5. The polyethylene glycol is free of material capable of being removed by filtration through a 10 micron filter. It further has been found that a solution of the type described can be used for heart preservation as a perfusate in a process in which the perfusate is flowed through the circulatory system of a heart muscle at a low flow rate not exceeding about 6 ml per gram of heart weight per hour. The solution may be used for cardioplegia applications, and 4 hours of cardioplegic heart preservation can be achieved without significant loss of viability
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The polyethylene glycol ingredient of solutions of the instant invention has an average molecular weight that is at least about 15,000 daltons and preferably is in the range of from about 15,000 to about 20,000 daltons. The high molecular weight polyethylene glycol desirably may be made through a process in which hydroxy-functional lower molecular weight polyethylene glycols are linked together using, as linking moieties, such diepoxidies as the diglycidyl ether of Bisphenol A. When polyethylene glycol having an average molecular weight of about 8000 daltons is linked in this manner, the resulting material will include some polymer having an average molecular weight of about 8000 daltons, some polymer having an average molecular weight of about 16,000 daltons, and some higher molecular weight polymers generally thought to be multiples of the 8000 dalton material. The initial 8000 dalton material, of course, itself has a molecular weight distribution, and as a result the high molecular weight polyethylene glycol used in the invention has a broad molecular weight distribution. At least about 60 weight percent of the high molecular weight polyethylene glycol, however, is about 15000 daltons or greater in molecular weight. High molecular weight polyethylene glycol is available commercially, as from Union Carbide Corporation.
Of importance, the polyethylene glycol ingredient must be free of particulate or other material that is retained on a 10 micron (preferably a 5 micron) filter. During development of the instant invention, it was found that polyethylene glycol of the type described may contain particulate or gel or other material which, when employed in a perfusion operation, tends to block capillary flow, leading to rapid loss of viability of the organ being treated. The polyethylene glycol ("PEG") is water soluble, and commonly is dissolved at a low concentration in water, following which the solution may be filtered through appropriate filters such as Millipore brand filters to remove the unwanted material. Various filtering methods can be employed. In a preferred embodiment, the polyethylene glycol solution is filtered through ten micron filters and preferably two or more such filters in series. The purpose of the filtration step is to remove particulate or gel or other material that is harmful to organ preservation. Filtration of the PEG solution through 0.2 micron cartridge filters has the additional advantage of rendering the solution bacteriologically sterile.
Desirably, the concentration of the PEG in organ preservation solutions of the invention is maintained in the range of about 4% to about 10% by weight. The desirable effects which are provided by the PEG material are displayed for the most part at concentrations of about 3% by weight or greater. On the other hand, the PEG employed in the instant invention is of sufficiently high molecular weight as to unduly increase the viscosity of an aqueous perfusate solution when the PEG is employed in concentrations exceeding about 10% by weight. Approximately 5% PEG concentrations have yielded excellent results.
The high molecular weight polyethylene glycol employed in the instant invention provides perfusion and cardioplegic flush solutions with unexpectedly good organ preservation capabilities. Although it is believed that in some applications the polyethylene glycol functions as a colloid to keep the perfusate in the vascular system, and that it may interact in some beneficial way with cell membranes, the precise technical explanation for the surprisingly beneficial properties of this material in organ preservation is not known.
The perfusates of the invention may include a variety of further ingredients common to organ preservation, e.g., perfusate solutions in general. Typical ingredients include:
______________________________________Ingredient Amount Function______________________________________NaOH 30-40 mM Provide buffering of ingredients to desired pHLactobionic acid 100 mM Impermeant anion, chelation of calcium and ironKH.sub.2 PO.sub.4 25 mM Provides potassium and phosphate for bufferingKOH 100 mM Potassium to prevent loss of intracellular cation and for cardioplegia, OH neutralizes lactobionic acidImpermeant non- 30 mM Further impermeant to controlelectrolyte, cell swellingtypically raffinoseGlutathione 3 mM Control of redox potential and protection against free radical injury______________________________________
The solution preferably is devoid of nutrients that are metabolized by the organ to be preserved.
EXAMPLE 1
This example describes the use of an organ preservation solution of the invention for cardioplegia and short term heart preservation in an experimental model designed to imitate the conditions of open heart surgery likely to be encountered clinically in operations on the arrested heart. The test was conducted at 15° C. to simulate realistic conditions.
Candidate cardioplegic solutions were prepared as shown in the following Table 1 in which a solution of the invention was designated Solution "A". Solution "B" was the well known and widely used St. Thomas II solution commonly employed in human heart surgery and for cardiac transplantation. Solution "C" was a perfusate solution containing hydroxyethyl starch ("HES") commonly known as the "UW" solution and reported in Heart Transplantation 7:456, 1988.
TABLE 1______________________________________Ingredient Solution A Solution B Solution C______________________________________ mM mM mMNa (as NaOH) 40 120 30K (as KOH) 125 16 125Ca -- 1.2 --Mg 5 16 5H.sub.2 PO.sub.4 25 -- 25SO.sub.4 5 -- 5Lactobionate 100 -- 100Raffinose 30 -- 30Cl -- 160 --HCO.sub.3 -- 10 --Polyethylene glycol.sup.(1) 50 Gm/L -- --HES -- -- 50 Gm/LAdenosine -- -- 5Glutathione 3 -- 3Allopurinol -- -- 1Insulin -- -- 100 UnitsPenicillin -- -- .133 Gm/LDexamethasone -- -- .008 Gm/L______________________________________ .sup.(1) Polyethylene glycol compound "20M", Union Carbide Corporation.
New Zealand white rabbits weighing 2-3 kgs were anesthetized using sodium pentobarbital, and supported on a ventilator via a trachesotomy. A median sternotomy was performed and the heart rapidly excised (5-10 sec) and immersed in iced saline. An occlusive cannula was immediately placed in the aorta, and 15-25 ml of one of the above cardioplegic solutions were infused (4° C.) at a pressure of 100 cm H 2 O. Thereafter, hearts were kept in a water bath at 15° C. for a total of 4 hours. During the first two hours, each heart was reflushed with the cardioplegic solution every 30 minutes in order to simulate clinical practice in which the arrested heart is reflushed approximately every 30 minutes.
After the preservation period, the aorta and left atrium (LA) were cannulated and the hearts were functionally evaluated on an ex vivo perfusion circuit filled with oxygenated Krebs Henseleit solution at 37° C. The test apparatus was similar to that originally described by Neely, et al. (Neely J. R., Liebermeister H., Battersby E. J., et al. Am. J. Physiol. 1967; 212: 804). The hearts were allowed 15 minutes of recovery while on retrograde Langendorff perfusion at a pressure of 100 cm H 2 O. This was converted to a working heart mode for a 45-minute test period: The LA pressure was kept at 20 cm H 2 O and the aortic outflow was connected to a column in which the overflow was set at 100 cm H 2 O. Measurements of aortic pressure, coronary and aortic flow rates were made and recorded at 1 hour and cardiac output was calculated.
Hearts preserved by each of the three cardioplegic solutions were tested for cardiac output as described above, and that output was compared to the cardiac output of hearts flushed with each of these solutions and tested immediately with no storage period. The observed results were as follows:
TABLE 2______________________________________Candidate Cardioplegic Mean Cardiac Output, ml/gSolution (No. of Hearts Tested)______________________________________Control Solution A 38.30 ± 2.42 (6)(no Solution B 20.51 ± 8.26 (5)storage) Solution C 26.47 ± 2.27 (6)Test Solution A 37.00 ± 6.53 (5)(4 hour Solution B 17.40 ± 0.86 (4)storage) Solution C 27.80 ± 11.07 (5)______________________________________
Tetrazolium staining revealed diffuse macroscopic infarcts in all hearts treated with Solution B and in one of the 5 hearts treated with Solution C. No infarcts were observed in any of the control hearts, or in any of the test hearts treated with Solution A. The results indicate that the solution of the invention provided substantially improved protection of hearts from injury under realistic conditions in comparison with conventional cardioplegic solutions.
EXAMPLE 2
This example describes the use of an organ preservation solution of the invention employed in a technique involving continuous hypothermic perfusion at very slow rates.
New Zealand white rabbits weighing 2-3 kgs were each anesthetized using sodium pentobarbital, and supported on a ventilator via a tracheostomy. Median sternotomies were performed and the hearts excised and immersed in iced-saline. An occlusive cannula was immediately placed in the aorta of each heart, and 15-25 ml of flush solution infused (4° C.). Extraneous tissue was removed and each heart was rapidly weighed.
The aorta of each heart was tied to a cannula fitted through the lid of a small plastic specimen container in order to stabilize it during the subsequent perfusion period. The container was provided with an outlet port to permit effluent to escape, assuring that the aortic root remained stable and the aortic valve shut so that perfusate passed through the coronary vessels rather than the aortic valve.
Control groups consisted of (a) 6 unstored hearts which had been rapidly removed cooled and arrested with "UW" (a hydroxyethyl starch perfusate reported in Table 3 below) and then immediately functionally evaluated, (b) 6 unstored hearts cooled and arrested with a solution identical to the UW solution but containing polyethylene glycol of molecular weight approximately 15,000-20,000 daltons in place of hydroxyethyl starch, (c) 9 hearts treated as in group (a) and then ice stored for 24 hours, and (d) 11 hearts subjected to low pressure oxygenated perfusion with a cardioplegic solution designated "WP" (Table 3).
Hearts in the experimental groups were perfused at a rate of 3-6 ml/Gm/24 hours with the perfusates reported in Table 3 below. This very low delivery rate was achieved by the use of electrically driven syringe pumps or IV infusion pumps. The solutions were maintained at 0° C. Ten hearts (Experimental group (1)) were perfused with UW solution prepared within 24 hours of use. Experimental group (2) (16 hearts) were perfused with UW solution which had been shelf stored in double plastic bags for 4-6 months. Experimental group (3) (5 hearts) were perfused with UW solution containing no hydroxyethyl starch and Experimental Group (4) (14 hearts) were perfused with the UW solution in which the hydroxyethyl starch had been replaced with 5% polyethylene glycol of molecular weight in the range of approximately 15,000 to 20,000 daltons. The high molecular weight polyethylene glycol reported in this example was that identified in Example 1. In each case, the penicillin, dexamethasone and insulin were added immediately before use. The high molecular weight polyethylene glycol ingredient had been dissolved in water and passed three times through 10 micron Millipore brand filters to remove small amounts of contaminants. Finally, 6 hearts (Experimental Group 5) were perfused with the solution of Experimental Group 4 from which the insulin, penicillin, dexamethasone, adenosine and allopurinol had been omitted. After the 24-hour perfusion period, the aorta and left atrium were cannulated and the hearts were functionally evaluated at 37° C. on an ex vivo perfusion circuit as described in Example 1.
The individual results are summarized in Table 4. The significance of the experimental group data was compared with fresh controls, groups (a) and (b), and 24-hour UW perfused hearts, group (1). The group (a) hearts achieved a cardiac output ("CO") of 26.48±2.25 ml/Gm/min. This was significantly inferior to the CO of group (b) (38.30±2.42 ml/Gm/min) indicating that the high molecular weight polyethylene glycol solution was superior to the standard UW solution (group (a)) for short term cardioplegia. Those hearts undergoing oxygenated perfusion with WP solution, group (d), had a mean CO of 21.19±6.20. This was significantly inferior to the CO of hearts perfused slowly for 24 hours with UW solution and the two high molecular weight polyethylene glycol solutions (Experimental Groups (1), (4) and (5)), respectively. Hearts perfused slowly with solution containing HES as the colloid showed excellent function after storage (CO 28.72±7.69), indistinguishable from unstored control group (a) but significantly inferior to the high molecular weight polyethylene glycol control group (b). The high molecular weight polyethylene glycol perfusate led to a CO after 24-hour perfusion (31.52±4.49 group (4), and 31.67±3.43 group (5)) that was actually significantly higher than the HES-UW fresh controls (group a). However, all of experimental groups (1,4, and 5) showed a significantly lower CO after 24-hour perfusion than was found in the fresh polyethylene glycol solution controls (group (b)). This implies that there was a measurable amount of loss of function after 24-hour storage by comparison with the best control group (group (b)).
Omitting the HES or polyethylene glycol colloid from the UW solution was very detrimental in this model. The mean CO in Exp. group (3) fell to 11.44±5.24 ml/Gm/min, significantly below both fresh controls and the freshly prepared solutions in groups 1,4, and 5. Similarly, comparatively poor function followed simple ice storage with UW for 24 hours without microperfusion, (Control Group (c)). The mean CO in this group was 12.84±10.03 ml/Gm/min (P<0.01 vs group (a) and group (1)).
Experimental group (2) in which the UW solution had been shelf stored in plastic bags for 4-6 months, yielded a mean CO significantly lower than with HES-UW made up fresh before use (Experimental Group (1)). It would appear that this effect is due to oxidation of the glutathione during shelf storage.
These data suggest that simple ice storage of the heart with the flush solution generally accepted heretofore to have the best composition (UW solution) yields inadequate function after 24-hour storage. This failure is probably due in part to the accumulation of waste products and the development of acidosis. Although we do not wish to be bound by the following explanation, it appears that low flow rate perfusion and the UW solution and the solution of Experimental Groups 4 and 5 (at rates ranging from 3 to about 6 ml/Gm tissue/24 hours) offers support of anaerobic metabolism by provision of substrate, control of acidosis, and removal of waste products. This process leads to significant improvement in cardiac performance to levels that are either equal to or only a little below fresh unstored controls. In this low flow perfusion method the presence of a colloid appears to be essential. Of the colloids tested, high molecular weight polyethylene glycol yields surprisingly good results and would seem to be the best. Higher rates of perfusion in the presence of oxygen utilizing a modified cardioplegic solution (Control Group (d)) resembling St. Thomas II solution yielded results that were clearly inferior to hypoxic, low flow perfusion. Flow rates of conventional continuous perfusion methods (on the order of 1 ml/Gm/min) are approximately 500 times greater than the flow rates desirably employed utilizing the perfusate of the invention.
TABLE 3__________________________________________________________________________COMPOSITION OF PERFUSION SOLUTIONS Amount mM/L Control Group Exp. Group Exp. Group (3) Exp. Group (4) Exp. Group (5)Substance "WP" (1)&(2) UW UW. No HES High MWPEG High MWPEG__________________________________________________________________________Na 126 30 30 30 30K 8 125 125 125 125Ca 0.6 -- -- -- --Mg 14 5 5 5 5Cl 127 -- -- -- --HCO.sub.3 -- -- -- -- --H.sub.2 PO.sub.4 8 25 25 25 25SO.sub.4 14 5 5 5 5Lactobionate -- 100 100 100 100Raffinose -- 30 30 30 30Glucose 11 -- -- -- --Mannitol -- -- -- -- --Taurine 4 -- -- -- --Glycerol 136 -- -- -- --Sucrose 7 -- -- -- --Polyethylene glycol.sup.1 1 Gm/L -- -- -- --Chlorpromazine 0.010 -- -- -- --Procaine 1 -- -- -- --Phenoxybenzamine 0.007 -- -- -- --Adenosine -- 5 5 5 5Glutathione -- 3 3 3 3Insulin -- 100 U/L 100 U/L 100 U/L --Penicillin -- .133 Gm/L .133 Gm/L .133 Gm/L --Dexamethasone -- 8 mg/L 8 mg/L 8 mg/L --Hydroxyethyl starch -- 50 Gm/L -- -- --Allopurinol -- 1 mg/L 1 mg/L 1 mg/L --Polyethylene glycol.sup.2 -- -- -- 50 Gm/L 50 Gm/L__________________________________________________________________________ .sup.1 Mol. wgt. of approximately 8,000 daltons. .sup.2 Mol. wgt. of approximately 15,000-20,000 daltons.
TABLE 4__________________________________________________________________________ # Reaching Cardiac OutputGroup 100 cm H.sub.2 O (ml/Gm/min) Significance__________________________________________________________________________Controls(a) (UW) 6/6 26.48 ± 2.25(b) (High MWPEG) 6/6 38.30 ± 2.42 vs (a) p < 0.01(c) ((a) + ice stored) 5/9 12.64 ± 10.03 vs (a) p < 0.01(d) (Oxygenated perfusion) 11/11 21.19 ± 6.20 vs (a) NSExperimental Groups(1) UW Fresh 10/10 28.72 ± 7.69 vs (a) NS vs (b) p < 0.01(2) UW Shelf stored 8/16 17.29 ± 9.27 vs (1 & 2) p < 0.01(3) UW No HES 2/5 11.44 ± 6.24 vs (1 & 2) p < 0.01(4) UW with high 14/14 31.52 ± 4.48 vs (a) p < 0.05MW PEG (5%) vs (b) p < 0.01(5) UW with high 6/6 31.67 ± 3.43 vs (4) NSMW PEG (5%) vs (1) NS(less insulin andother ingredients)__________________________________________________________________________
EXAMPLE 3
The ingredients of the organ preservation solutions of the invention can be varied widely, and compositions of the invention (in distilled water and sterilized by filtration through a 0.2 micron filter) have given good results in a small number of dog kidney and heart experiments, and pig heart experiments. Because of technical difficulties associated with large animal heart preservation studies, the data is qualitative rather than quantitative and involves the ability of the heart to beat vigorously and in some cases sustain the circulation of the animal for a few hours with minimum doses of cardiotonic drugs.
Two dog kidneys have successfully been preserved for 48 hours using low flow perfusion, as described below. In one case, the perfusate was UW containing hydroxyethyl starch (solution of Experimental Group (1) from Example 2) and in the second the solution was the following solution containing 5% high molecular weight polyethylene glycol ("20M", Union Carbide):
______________________________________Ingredient Concentration, mM______________________________________Potassium lactobionate 100KH.sub.2 PO.sub.4 25MgSO.sub.4 5Raffinose 30NaOH.sup.1 30-40Glutathione (reduced) 3PEG, 5mol. wgt. approx. 5% by weight(15,000-20,000 daltons)______________________________________ .sup.1 Added to provide a final pH 24 hours after initial formulation of the solution, in the range of 7.1-7.45.
For each solution, the left kidney was removed from an anesthetized mongrel dog, immediately flushed with 150 ml of the solution and immersed in ice saline. Thereafter, a cannula was tied into the renal artery and the perfusate solution a 0° C. was perfused through the artery for 48 hours using an electrically driven syringe pump at a rate of 3 ml/Gm/24 hours. At the end of this time, the dog was again anesthetized, the contralateral kidney removed and the preserved kidney transplanted into the right side of the pelvis using conventional vascular and ureter-to bladder anastomosis techniques. Blood samples were taken daily for the following week and serum creatinine levels measured. The maximum serum creatinine in the dog receiving the kidney perfused with UW was 3.4 mg % and in the other dog receiving the kidney preserved with the high molecular weight polyethylene glycol solution was 3.0 mg %. This preliminary data suggests that the latter solution may be equally as effective as the UW solution for kidney preservation and that the low flow perfusion technique may be beneficial in the kidney as it has been shown to be for the heart.
While a preferred embodiment of the present invention has been described, it should be understood that various changes, adaptations and modifications may be made therein without departing from the spirit of the invention and the scope of the appended claims. | An organ preservation solution, particularly valuable in the preservation of mammalian hearts intended for transplantation, in aqueous solution, at least about 3% by weight of polypropylene glycol having an average molecular weight of at least about 15,000 daltons and being free of material retained by 10 micron filtration, a buffer buffering the pH of the solution perfusate to a value in the range of about 7.1 to about 7.5, and an impermeant composition for retarding the passage of water across cell membranes of an organ treated with the solution. | 0 |
BACKGROUND AND SUMMARY OF THE INVENTION
The invention relates to electronic fuel injection systems for internal combustion engines which employs an auxiliary air port to by-pass the throttle blade. More specifically, the invention relates to the art of varying the amount of auxiliary air which by-passes the throttle blade by changing the variable cross sectional opening of the auxiliary air port actuator in response to electrical pulses from a controller. The pulses are based on RPM changes due to changing loads on the engine. This air by-pass actuator is especially helpful at very low engine idle speeds where the throttle blade is nearly closed. The auxiliary air is supplied via the actuator in the by-pass port to control idle speed in response to engine loads, such as that due to air conditioning, automatic transmission, electrically heated backlights, etc.
An air by-pass valve representative of the prior art appears in U.S. Pat. No. 4,325,349.
One of the objects of the invention is to provide an auxiliary air by-pass actuator valve which is small in size.
Another object of the invention is to provide an auxiliary air by-pass actuator valve which can quickly respond to changing engine load signals.
The actuator valve described and claimed herein employs an air passage, which comprises a D-shaped orifice, a D-shaped notch and multiple orifices, gear reduction means and a motor assembly to drive the valve between the open and the closed postions, and a clutch assembly which helps to prevent the stalling of the motor if the valve reaches the full open or full closed position stops.
Accordingly, the present invention has among its further objects to provide an improved form of actuator valve employing a generally D-shaped valve and multifingered clutch.
The above and other objects and advantages of the invention will appear more fully from consideration of the following detailed description of the preferred embodiment of the invention made with reference to the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the subject actuator assembled into a throttle body. The Figure also shows one type of throttle body in a partial cut-away view to illustrate one typical air-flow pattern through the assembly.
FIG. 2 is an end view of the actuator showing the D-shaped valve and orifice along one typical air-flow pattern through the actuator.
FIG. 3 is a horizontal view of the actuator with a partial cross-section revealing the contoured surface, the D-shaped valve member and the clutch.
FIG. 4 is an exploded view of the D-shaped valve, the clutch and the associated hardware.
FIG. 5 is a left-hand view of the contoured surface of the actuator showing the D-shaped valve in a partially open position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the automatic idle speed actuator assembly 10 is shown mounted into a throttle body assembly 12. The separate air passage which by-passes the throttle blade in throttle body assembly 12 is shown as 11. The by-pass air is shown schematically in FIG. 1 with the use of arrows 14. It is to be appreciated that in different types of throttle body assemblies, the direction of the air-flow may be reversed.
Referring to FIG. 2, the operation of the actuator assembly 10 and the movement of air-flow 14 is further illustrated. Shown in housing 22 along with contoured suface 34. Working with contoured surface 34 is the D-shaped disc 39. Contoured surface 34 and D-shaped disc 39 work together to vary the orifice opening 32. This allows the amount of air-flow received across contoured surface 34 to enter into orifice 32 and then be expelled through multiple-orifices 36. It is to be appreciated that this air-flow pattern can be reversed for different throttle body designs.
Referring now to FIG. 3, throttle body assembly 10 is featured in a partial cut-away view. The main exterior parts to the actuator assembly 10 are the valve assembly housing 22, the motor assembly 20 and the attachment flanges 26. These external components are all held together by means of motor retaining clamp 24.
Throttle body assembly 10 is inserted into the throttle body assembly 12 and is retained there by attachment means through flanges 26. A seal is made between throttle body assembly 12 and actuator assembly 10 by the combination of O-ring grooves 28 and 30 along with O-rings 29 and 31. The cut-away portion of FIG. 3 further shows the D-shaped orifice 32 for acceptance or exhaust of the air-flow. Also shown is contoured surface 34 and pivot pin 50. The valve element 38 is made up basically of D-shaped disc 39 and D-shaped notch 40. The valve element 38 contains a valve locating hole 48, shown in FIG. 4, to mate with pivot pin 50. The valve element 38 frictionally communictes with the bearing surface 35 by means of bearing surface 47 on D-shaped disc 39. Valve element 38 rotates about pivot pin 50 in such a manner as to open or close D-shaped orifice 32. The amount of D-shaped opening 32 which is encroached by D-shaped disc 39 determines the amount of air-flow 14 which passes through D-shaped orifice 32. The generally cylindrical housing member 22 contains multiple orifices 36 on the circumference of the housing. The multiple orifices 36 are allowed to communicate with the air-flow 14 by means of valve element 38. In the particular embodiment shown in FIG. 3 the air-flow 14 would be allowed to enter through D-shaped orifice 32 and flow past D-shaped notch 40 on out through one or several of the multiple orifices 36.
A more detailed view of operation of the actuator can now be approached by referring to FIGS. 3, 4 and 5. Valve member 38 also comprises a bearing surface 47 which aids in frictional communication between valve member 38 and bearing surface 35. Valve stops 44 protrude from the circumference of D-shaped disc 39 and communicate with housing stops 46 when the D-shaped valve element 38 is selectively rotated to its end of travel.
FIG. 4 is an exploded view which illustrates the valve and clutch assembly 37. Valve element 38 is generally cylindrical. Illustrated are exterior cylindrical clutch surface 54 and interior cylindrical clutch surface 53. Valve shaft means 52 mates with reaction plate bore 66 to centrally locate reaction member 57 into valve element 38.
Reaction member 57 is comprised of reaction plate 62 which frictionally communicates within the interior of valve element 38 on interior clutch surface 53. The reaction member 57 is held in place with the valve element 38 by means of retaining clip 68 which fits over valve shaft 52.
Reaction member 57 further comprises tabs 64 which radially project from the circumference of the reaction member.
The last major portion of the valve and clutch assembly 37 is the multi-fingered clutch member 56. The multi-fingered clutch member 56 is of generally cylindrical shape as is valve element 38 and reaction member 57. A spring 70 inserts between reaction member 57 and multi-fingered clutch 56. The cylindrical wall of multi-fingered clutch member 56 is made up of fingers 59. It is open at one end. The multi-fingered clutch member 56 further comprises a clutch torque ring groove 58. The multi-fingered clutch member 56 slides over valve element 38 and reaction member 57 such that the tabs 64 insert between the fingers 59 and past clutch torque ring groove 58 of multi-fingered clutch 56. The clutch torque ring 60 then slides over the assembly 37 and into clutch torque ring groove 58 thereby locking the assembly.
The spring 70 urges communication between the reaction member 57 and the valve element 38. The multi-fingered clutch 56 communicates with the radially projecting tabs 64 of reaction member 57 and is resiliently mated to the reaction member 57 via the spring 70. The clutch torque ring 60 provides frictional contact and retaining force between reaction member 57 and the multi-fingered clutch member 56.
In general the operation of the actuator is as follows:
The air passage represented by D-shaped orifice 32, the contoured surface 34, D-shaped notch 40 and valve element 38, along with multi-orifices 36 controls the amount of air-flow 14 into the throttle body assembly 12 for idle speed control. The amount of air-flow 14 is determined by the relative position of the D-shaped orifice 32 and the valve element 38. The maximum air-flow 14 of the valve fully open is determined by the shape of the contoured surface 34, the size and shape of the D-shaped notch 40, and the size and shape and number of the multiple orifices 36.
The minimum air-flow of the valve fully closed is determined by the bearing surface height 47 and the loading produced by the spring 70.
The clutch prevents the stalling of the motor when the valve assembly reaches its stop position, either full open or full closed, thereby preventing the high current associated with the stall of the motor. Communication between the actuator valve and the motor is provided by a gear reduction assembly means and shaft blocked out as 19 in FIG. 3. Motor controls are not shown but in general comprise decision making circuitry and software which energizes the motor with the desired polarity for the desire time period.
The subject valve works by sliding its valve members perpendicular to engine vacuum. The subject valve therefore requires a small force to actuate. Other types of idle speed motors actuate valve members in the same direction as engine vacuum. Overcoming the vacuum to open the air by-pass orifice to by-pass air requires stronger, heavier and larger motors than the subject valve.
Although D-shaped pieces and orifices are utilized in the preferred embodiment, other shaped valve members, discs and orifices etc., could also be used depending on the application. The D-shape employed in the preferred embodiment lends itself well to the required air-flow in an air by-pass orifice.
The material of which the multi-fingered clutch 56 is made and also the material of the valve 38 and the exterior clutch surface 54 are selected specifically to have specific friction coefficients. These materials when combined with the loading of clutch torque ring 60 allows a motor current during clutch operation or clutch slip that is not much higher than actual operation current. In one typical embodiment of the subject invention, the multi-fingered clutch is made of a nylon based material and the valve element is made of sintered iron. Also, the clutch torque ring is made of steel wire, the wire diameter of the ring is selected to provide proper loading on the multi-fingered clutch assembly to give the right clutch frictional surface characteristics.
While the above description constitutes the preferred embodiment of the present invention, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope or fair meaning of the accompanying claims. | An auxiliary air by-pass actuator valve of small size is disclosed which provides a quick response to the changing RPM of the engine due to changing loads. The actuator employs a stationary D-shaped orifice in communication with a rotatable valve member and D-shaped disc to regulate the amount of auxiliary air which by-passes the throttle blade in an electronic fuel injection system. | 5 |
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